Heterogeneous polymer blend and process of making the same

ABSTRACT

A heterogeneous polymer blend comprises a continuous phase comprising a thermoplastic first polymer having a crystallinity of at least 30% and a dispersed phase comprising particles of a second polymer different from the first polymer dispersed in said continuous phase, the second polymer having a crystallinity of less than 20% and being at least partially cross-linked, and the average particle size of the particles of the second polymer being less than 1 micron.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims benefit of U.S. Provisional Application Ser. No. 60/693,030 filed Jun. 22, 2005.

BACKGROUND

Heterogeneous polymer blends comprising a second polymer dispersed in a matrix of a first polymer are very useful and, depending on the properties and the relative amounts of the first and second polymers, a wide variety of such polymer blends can be produced. Of particular interest are polymer blends, also referred to as thermoplastic elastomers, in which the first polymer is a thermoplastic material, such as polypropylene, and the second polymer is an elastomeric material, such as an ethylene-propylene elastomer or an ethylene-propylene-diene (EPDM) rubber. Examples of such thermoplastic elastomers include polypropylene impact copolymers, thermoplastic olefins and thermoplastic vulcanizates.

Unlike conventional vulcanized rubbers, thermoplastic elastomers can be processed and recycled like thermoplastic materials, yet have properties and performance similar to that of vulcanized rubber at service temperatures. For this reason, thermoplastic elastomers are useful for making a variety of articles such as weather seals, hoses, belts, gaskets, moldings, boots, elastic fibers and like articles. They are also particularly useful for making articles by blow molding, extrusion, injection molding, thermo-forming, elasto-welding and compression molding techniques. In addition, thermoplastic elastomers are often used for making vehicle parts, such as but not limited to, weather seals, brake parts including, but not limited to cups, coupling disks, diaphragm cups, boots such as constant velocity joints and rack and pinion joints, tubing, sealing gaskets, parts of hydraulically or pneumatically operated apparatus, o-rings, pistons, valves, valve seats, and valve guides.

One method of making the aforementioned polymer blends is by mixing two different polymers after they have been polymerized to achieve a target set of properties. However, this method is relatively expensive making it much more desirable to make blends by direct polymerization. Blending by direct polymerization typically uses multiple reactors in series, where the product from one reactor is fed to a second reactor having a different polymerizing environment, resulting in a final product that is an intimate mix of two different products. Examples of such processes employing vanadium catalysts in series reactor operation to produce different types of EPDM compositions are disclosed in U.S. Pat. Nos. 3,629,212, 4,016,342, and 4,306,041.

U.S. Pat. No. 6,245,856 discloses a thermoplastic olefin composition comprising polypropylene, an ethylene-alpha olefin elastomer and a compatabilizer comprising an ethylene-propylene copolymer having a propylene content of greater than 80 weight percent. According to this patent, the individual components of the composition can be separately manufactured and mechanically blended together in a mechanical mixer or two or more of the components can be prepared as a reactor blend using a series of reactors where each component is prepared in a separate reactor and the reactant is then transferred to another reactor where a second component is prepared. In the absence of the compatabilizer, the elastomer phase is said to be uneven with particles greater than 5 microns in size, whereas the addition of the compatabilizer is said to improve dispersion such that the elastomer phase has a particle size of about 1 micron. The elastomer phase of this polymer blend is not cross-linked.

U.S. Pat. No. 6,207,756 describes a process for producing a blend of a continuous phase of a semi-crystalline plastic, such as polypropylene, and a discontinuous phase of an amorphous elastomer, such as a terpolymer of ethylene, a C₃-C₂₀ alpha olefin and a non-conjugated diene. The blends are produced in series reactors by producing a first polymer component in a first reactor, directing the effluent to a second reactor and producing the second polymer component in solution in the second reactor in the presence of the first polymeric component. U.S. Pat. No. 6,319,998 also discloses using series solution polymerizations to produce blends of ethylene copolymers. U.S. Pat. No. 6,770,714 discloses the use of parallel polymerizations to produce different polymeric components that are then blended through extrusion or using other conventional mixing equipment. One polymeric component is a propylene homopolymer or copolymer and the second polymeric component is an ethylene copolymer.

One particularly useful form of thermoplastic elastomer is a thermoplastic vulcanizate (“TPV”), which comprises a thermoplastic resin matrix, such as polypropylene, within which are dispersed particles of a cured elastomeric material, such as an EPDM rubber. TPVs are normally produced by a process of “dynamic vulcanization”, which is a process of vulcanizing or cross-linking the elastomeric component during intimate melt mixing with the thermoplastic resin, together with plasticizers (e.g. process oils), fillers, stabilizers, and a cross-linking system, under high shear and above the melting point of the thermoplastic. The mixing is typically done in a twin-screw extruder, to create a fine dispersion of the elastomeric material within the thermoplastic resin while the elastomeric material is cured. The levels of thermoplastic resin and plasticizer (oil) can be adjusted to produce grades having different profiles of hardness, rheology and engineering properties, although in general it is difficult to produce TPVs by dynamic vulcanization in which the content of the elastomeric phase is greater than 50 wt % of the overall polymer blend. Examples of dynamic vulcanization are described in the U.S. Pat. Nos. 4,130,535 and 4,311,628.

However, while dynamic vulcanization is effective in producing TPVs with a unique profile of properties, it is expensive and suffers from a number of disadvantages. Thus the production of quality product is technically challenging and specialized equipment is needed. Moreover, the process involves many steps, each one critical to the eventual quality of the final product. Forming the polymer blend normally involves separately comminuting bales of the elastomeric polymer (which is typically how EPDM rubber is commercially distributed), mechanically mixing it with the thermoplastic resin along with the processing oils, curatives, and other ingredients in a suitable high shear mixing device to comminute the rubber particles and cure them to generate cured rubber particles embedded in a continuous thermoplastic resin matrix. The cured rubber particles in the finished products have an averaged particle size of 1 to 10 microns. Careful injection of processing oil helps manage the rheological characteristics of the fluid in the reactive extruder (to minimize pressure buildup) as well as product properties such as hardness. Precise control over the size and distribution of the cross-linked elastomer particles is sought, as it affects properties such as elastic recovery (as measured through compression set). While the products produced with existing technology have many desirable properties, there are gaps in the overall properties profile. Some of these are the need for higher service temperatures, improved elastic recovery, softer products, higher tensile strength, easier processability, oil-free compositions, and/or colorless products.

An improved process for producing TPVs is disclosed in U.S. Pat. No. 6,388,016, incorporated herein in its entirety, in which a polymer blend is produced by solution polymerization in series reactors employing metallocene catalysts and the resultant blend is subjected to dynamic vulcanization. In particular, the process involves feeding a first set of monomers selected from ethylene and higher alpha-olefins, and a solvent, to a first continuous flow stirred tank reactor, adding a metallocene catalyst to the first reactor in an amount of 50 to 100 weight % of the total amount of catalyst added to all reactors, operating the first reactor to polymerize the monomers to produce an effluent containing a first polymer, feeding the effluent from the first reactor to a second continuous flow stirred tank reactor, feeding a second set of monomers selected from ethylene, higher alpha-olefins and non-conjugated dienes, and optionally additional solvent, to the second reactor, operating the second reactor to polymerize the second monomers to produce a second polymer containing diene, recovering the resulting first and second polymers and blending them with a curing agent under conditions of heat and shear sufficient to cause the blend to flow and to at least partially crosslink the diene-containing polymer and form a dispersion of cured diene-containing particles in a matrix of the first polymer. It will, however, be seen that this improved process still relies on dynamic vulcanization to cure the elastomeric component. As a result the cured diene-containing particles have an average particle size in the range of 1 to 10 microns

SUMMARY

In one aspect, the present invention relates to a heterogeneous polymer blend comprising:

-   -   (a) a continuous phase comprising a thermoplastic first polymer         having a crystallinity of at least 30%; and     -   (b) a dispersed phase comprising particles of a second polymer         different from the first polymer dispersed in said continuous         phase, the second polymer having a crystallinity of less than         20% and being at least partially cross-linked, and the average         particle size of the particles of the second polymer being less         than 1 micron.

In a further aspect, the present invention resides in a heterogeneous polymer blend comprising:

-   -   (a) a continuous phase comprising a thermoplastic first polymer         having a crystallinity of at least 30%; and     -   (b) a dispersed phase comprising particles of a second polymer         different from the first polymer dispersed in said continuous         phase, the second polymer having a crystallinity of less than         20% and being at least partially cross-linked, and the average         particle size of the particles of the second polymer being less         than 10 microns,         wherein said polymer blend is substantially free of processing         oil.

Preferably, said thermoplastic first polymer is a homopolymer of a C₂ to C₂₀ olefin or a copolymer of a C₂ to C₂₀ olefin with less than 15 wt % of at least one comonomer.

Preferably, the second polymer is produced from a plurality of comonomers comprising at least one C₃ to C₂₀ olefin and at least one polyene. Conveniently, the polyene has at least two polymerizable unsaturated groups and preferably is a diene.

Preferably, the average particle size of the particles of the second polymer is between about 50 nanometers and about 0.5 microns.

Conveniently, said dispersed phase comprises more than 50 wt %, such as more than 60 wt %, for example more than 70 wt % of the total heterogeneous polymer blend.

In a another aspect, the present invention resides in a heterogeneous polymer blend comprising:

-   -   (a) a continuous phase comprising a thermoplastic first polymer         that is at least partially crystalline; and     -   (b) a dispersed phase comprising particles of a second polymer         different from the first polymer dispersed in said continuous         phase, wherein said dispersed phase comprises at least a         fraction which is insoluble in xylene and which comprises less         than 10,000 ppm, such as less than 2,500 ppm, such as less than         1,000 ppm, such as less than 100 ppm, such as less than 10 ppm,         (preferably in the absence) of a curative.

Conveniently, said fraction insoluble in xylene comprises at least is at least 4%, such as at least 10%, such as at least 20%, such as at least 40%, such as at least 50%, of said dispersed phase.

In yet a further aspect, the invention resides in a process for producing a heterogeneous polymer blend comprising (a) a continuous phase comprising a thermoplastic first polymer that is at least partially crystalline; and (b) a dispersed phase comprising particles of a second polymer different from the first polymer dispersed in said continuous phase, the second polymer having a crystallinity less than that of the first polymer and being at least partially cross-linked, the process comprising:

-   -   (i) polymerizing at least one first monomer to produce a         semi-crystalline thermoplastic first polymer that is at least         partially crystalline; and     -   (ii) contacting at least part of said first polymer with at         least one second monomer and at least one polyene under         conditions sufficient to polymerize said second monomer to         produce said second polymer and also (preferably simultaneously)         cross-link said second polymer such that the dispersed phase         produced by said contacting (ii) comprises at least a fraction         which is insoluble in xylene.

In still a further aspect, the present invention resides in a process for producing a heterogeneous polymer blend, the process comprising:

-   -   (a) selecting a catalyst capable of polymerizing a C₂ to C₂₀         olefin to produce a first polymer having at least 30%         crystallinity;     -   (b) contacting said catalyst with one or more C₂ to C₂₀ olefins         at a temperature of at least 50° C. to produce a first polymer         having at least 30% crystallinity;     -   (c) contacting said first polymer and said catalyst with at         least one C₃ to C₂₀ olefin and at least one polyene under         conditions sufficient to polymerize said at least one C₃ to C₂₀         olefin to produce a second polymer and simultaneously cross-link         said second polymer, whereby the product of said contacting (c)         is a heterogeneous polymer blend comprising a continuous phase         of the first polymer having at least 30% crystallinity and a         discontinuous phase of particles of said second polymer having         an average particle size less than 3 microns, said second         polymer being at least partially cross-linked and comprising at         least 15 wt % of said C₃ to C₂₀ olefin and at least 0.0001 wt %         of said polyene.

Conveniently, said polyene has at least two polymerizable unsaturated groups.

Conveniently, said catalyst selected in (a) is a single site catalyst comprising at least one catalyst component, normally a metallocene, and at least one activator.

In still yet a further aspect, the present invention resides in a process for producing a heterogeneous polymer blend, the process comprising:

-   -   (a) selecting a catalyst capable of polymerizing a C₂ to C₂₀         olefin to produce a first polymer having at least 30%         crystallinity;     -   (b) contacting said catalyst with one or more C₂ to C₂₀ olefins         at a temperature of at least 50° C. to produce a first polymer         having at least 30% crystallinity;     -   (c) contacting said first polymer together with at least one C₃         to C₂₀ olefin and at least one polyene with a catalyst capable         of polymerizing bulky monomers under conditions sufficient to         polymerize said at least one C₃ to C₂₀ olefin to produce a         second polymer and simultaneously cross-link said second         polymer, whereby the product of said contacting (c) is a         heterogeneous polymer blend comprising a continuous phase of the         first polymer having at least 30% crystallinity and a         discontinuous phase of particles of said second polymer having         an average particle size less than 3 microns, said second         polymer being at least partially cross-linked and comprising at         least 15 wt % of said C₃ to C₂₀ olefin and at least 0.0001 wt %         of said polyene.

Conveniently, said catalyst employed in contacting (c) is capable of producing a polymer having an Mw of 20,000 or more and a crystallinity of less than 20%.

In one embodiment, the catalyst employed in contacting (c) is the same as the catalyst employed in contacting (b).

In another embodiment, the catalyst employed in contacting (c) is the different from the catalyst employed in contacting (b) and catalyst quenching is applied between the contacting (b) and the contacting (c).

DESCRIPTION OF THE DRAWINGS

FIGS. 1A and 1B are atomic force micrographs (AFM) of the polymer blend produced in Example 1A and 1B, respectively.

FIG. 1C is a transmission electron micrograph (TEM) of a molded part cross-section produced from the polymer blend of Example 1A.

FIG. 1D is a histogram of particle sizes for the polymer blend of Example 1A obtained from an AFM image.

FIG. 1E is a histogram of particle sizes for the polymer blend of Example 1A obtained from a TEM image.

FIG. 1F is a DSC trace of the xylene insolubles of Example 1B.

FIG. 1G is a transmission electron micrograph (TEM) of a molded part cross-section produced from the polymer blend of Example 1C

FIG. 1H are transmission electron micrographs (TEM) of molded part cross-sections produced from Santoprene 201-55 and 201-55F.

FIG. 2A is an atomic force micrograph (AFM) of the polymer blend produced in Example 2C.

FIG. 2B is a transmission electron micrograph (TEM) of a molded part cross-section produced from the polymer blend of Example 2C.

FIG. 2C is a Van Gurp-Palmen plot for Examples 1A and 2C, and Santoprene 201-55 and 201-73.

DETAILED DESCRIPTION

For purposes of this invention and the claims thereto when a polymer or oligomer is referred to as comprising an olefin, the olefin present in the polymer or oligomer is the polymerized or oligomerized form of the olefin, respectively. Likewise the use of the term polymer is meant to encompass homopolymers and copolymers. In addition the term copolymer includes any polymer having 2 or more monomers. Thus, as used herein, the term “polypropylene” means a polymer made of at least 50 weight % propylene units, preferably at least 70% propylene units, more preferably at least 80% propylene units, even more preferably at least 90% propylene units, even more preferably at least 95% propylene units or 100% propylene units.

As used herein the term “substantially free of processing oil” means that the relevant product contains little or no of the oil-based processing aids, such as extender oils, synthetic processing oils, oligomeric extenders, or a combination thereof, that are added to conventional polymer blends to control the rheological characteristics of the blends during dynamic vulcanization. Preferably the relevant product contains less than 1 weight % processing oil, more preferably less than 0.5 weight %, preferably less than 0.1 weight % processing oil. The amount of oil in the polymer blend is determined using solvent extraction as described the example section. By virtue of the fact that the second polymer of the polymer blend of the invention is formed as at least partially cross-linked particles dispersed in the first polymer phase in the polymerization reactor, the need for a subsequent dynamic vulcanization step and hence the need for addition of processing oil is avoided. It is, however, to be appreciated that in some cases the polymer blend of the invention may be subjected to post-polymerization curing and/or vulcanization to produce additional cross-linking of the second polymer.

As used herein the term “curative” means any of the additives conventionally added to polymer blends to effect curing of one or more components of the blend during a post-polymerization, dynamic vulcanization step. Examples of known curatives include sulfur, sulfur donors, metal oxides, resin systems, such as phenolic resins, peroxide-based systems, hydrosilation with platinum or peroxide and the like, both with and without accelerators and coagents.

As used herein the term “bulky monomer” means an olefin monomer that is not a linear C₂ to C₂₀ alpha olefin. Bulky monomers include cyclic olefin monomers, such as 5-ethylidene-2-norbornadiene, (ENB), 5-vinyl-2-norbornene (VNB) and cyclopentadiene; branched olefin monomers, such as 3,5,5 trimethyl hexene-1; and macromonomers, such as terminally unsaturated oligomers or terminally unsaturated polymers.

As used herein, the term “terminal unsaturation” is defined to mean vinyl unsaturation, vinylene unsaturation or vinylidene unsaturation, with vinyl unsaturation being preferred.

As used herein, the term “heterogeneous blend” means a composition having two or more morphological phases in the same state. For example a blend of two polymers where one polymer forms discrete packets such as finely divided domains dispersed in a matrix of another polymer is said to be heterogeneous in the solid state. Also a heterogeneous blend is defined to include co-continuous blends where the blend components are separately visible, but it is unclear which is the continuous phase and which is the discontinuous phase. Such morphology is determined using scanning electron microscopy (SEM) or atomic force microscopy (AFM). In the event the SEM and AFM provide different data, then the AFM data are used. By continuous phase is meant the matrix phase in a heterogeneous blend. By discontinuous phase is meant the dispersed phase in a heterogeneous blend.

In contrast, a “homogeneous blend” is a composition having substantially one morphological phase in the same state. For example a blend of two polymers where one polymer is miscible with another polymer is said to be homogeneous in the solid state. Such morphology is determined using scanning electron microscopy. By miscible is meant that that the blend of two or more polymers exhibits single-phase behavior for the glass transition temperature, e.g. the Tg would exist as a single, sharp transition temperature on a dynamic mechanical thermal analyzer (DMTA) trace of tan δ (i.e., the ratio of the loss modulus to the storage modulus) versus temperature. By contrast, two separate transition temperatures would be observed for an immiscible blend, typically corresponding to the temperatures for each of the individual components of the blend. Thus a polymer blend is miscible when there is one Tg indicated on the DMTA trace. A miscible blend is homogeneous, while an immiscible blend is heterogeneous.

The heterogeneous polymer blend of the invention comprises particles of an “at least partially cross-linked polymer”. These partially cross-linked polymers are believed to be formed by in-situ reaction between the polyene and the second polymers. The presence and amount of such partially cross-linked polymers in the blend can be determined by a multi-step solvent extraction process. In this process the direct product of the polymerization process, without undergoing any additional curing steps, is first contacted with cyclohexane at 25° C. for 48 hours to dissolve the uncured and lightly branched elastomeric components of the blend and then the remaining solids are refluxed at the boiling temperature of xylene for 24 hours with xylene to isolate the “at least partially cross-linked polymer”. The “at least partially cross-linked polymer” is also referred to herein as “xylene insolubles”. Details of the solvent extraction procedure are given in the Examples.

Melting temperature (T_(m)) and crystallization temperature (T_(c)), referred to herein, are measured using Differential Scanning Calorimetry (DSC) according to ASTM E 794-85. Details of the DSC test are given in the Examples. Heat of fusion (ΔH_(f)) is measured according to ASTM D 3417-99, and percentage crystallinity is calculated using heat of fusion as described below.

This invention relates to a heterogeneous polymer blend comprising a semi-crystalline (at least 30% crystalline) thermoplastic first polymer that constitutes the continuous phase and particles of a second polymer different from, and less crystalline than, the first polymer dispersed within the continuous phase. The dispersed particles have an average size of less than 10 micron, normally less than 3 micron, preferably less than 2 microns, more preferably less than 1 micron, and most preferably between about 50 nanometers and about 0.5 microns.

The inventive heterogeneous blends are believed to contain hybrid polymer. While not wishing to bound by theory, it is believed that some or all of the discrete particles of the second polymer are produced by means of an in-situ cross-linking chemistry that takes place concurrently with the synthesis of the second polymer and conveniently in the same polymerization reaction zone.

This invention also relates to a process for making the above polymer blend. In a reactor, a semi-crystalline polymer phase is produced in a first polymerization step. In a second polymerization step, the elastomeric phase is synthesized, in the presence of the semi-crystalline polymer phase. The elastomer phase takes the form of a fine particle size dispersion in the semi-crystalline phase. The elastomer phase is crosslinked through the use of multifunctional monomers, particularly a polyene having at least two polymerizable unsaturated groups, with the degree of crosslinking being controlled by the reaction environment during the polymerization. While not wishing to bound by theory, it is believed that reactive intermediates generated in the first reactor engage in the polymerization processes taking place in the second reactor, producing hybrid polymers (also known as branch-block copolymers) that combine the characteristics of the polymers formed in the first and second reactor zones, such as the melting temperature of the first polymer and the lower glass transition temperatures of the second polymer.

Following the two polymerization steps, the product composition, direct from the polymerization reactor, can undergo a typical polymer finishing operation, where suitable additives are incorporated and the polymer is melt homogenized. The finished product displays easy processability, high elastic recovery, high tensile strength and elongation. Heretofore, such properties were only possible via dynamic vulcanization.

The First Polymer

The matrix of the heterogeneous polymer blend of the present invention may be any crystalline or semi-crystalline thermoplastic polymer or a mixture thereof. Useful thermoplastic polymers have a crystallinity of at least 30%, more preferably at least 40% as determined by differential scanning calorimetry (DSC). The first polymer provides the composition with required tensile strength and temperature resistance. Accordingly, semi-crystalline polymers with a melting temperature, as measured by DSC, above 100° C., preferably above 120° C., preferably above 140° C. are desired. Typically, the first polymer has a crystallization temperature (T_(c)) between about 20 and about 120° C., such as between about 70 and about 110° C. Polymers with a high glass transition temperature to provide the elevated temperature resistance are also acceptable as the thermoplastic matrix.

Exemplary thermoplastic polymers include the family of polyolefin resins, polyesters (such as polyethylene terephthalate, polybutylene terephthalate), polyamides (such as nylons), polycarbonates, styrene-acrylonitrile copolymers, polystyrene, polystyrene derivatives, polyphenylene oxide, polyoxymethylene, and fluorine-containing thermoplastics. The preferred thermoplastic resins are crystallizable polyolefins that are formed by polymerizing C₂ to C₂₀ olefins such as, but not limited to, ethylene, propylene and C₄ to C₁₂ α-olefins, such as 1-butene, 1-hexene, 1-octene, 2-methyl-1-propene, 3-methyl-1-pentene, 4-methyl-1-pentene, 5-methyl-1-hexene, and mixtures thereof. Copolymers of ethylene and propylene or ethylene or propylene with another α-olefin, such as butene-1; pentene-1,2-methylpentene-1,3 -methylbutene-1; hexene-1,3 -methylpentene-1,4-methylpentene-1,3,3-dimethylbutene-1; heptene-1; hexene-1; methylhexene-1; dimethylpentene-1 trimethylbutene-1; ethylpentene-1; octene-1; methylpentene-1; dimethylhexene-1; trimethylpentene-1; ethylhexene-1; methylethylpentene-1; diethylbutene-1; propylpentane-1; decene-1; methylnonene-1; nonene-1; dimethyloctene-1; trimethylheptene-1; ethyloctene-1; methylethylbutene-1; diethylhexene-1 and dodecene-1, may also be used.

In one embodiment, the thermoplastic polymer comprises a propylene homopolymer, a copolymer of propylene, or a mixture of propylene homopolymers and copolymers. Typically, the propylene polymer is predominately crystalline, i.e., it has a melting point generally greater than 110° C., alternatively greater than 115° C., and preferably greater than 130° C. The term “crystalline,” as used herein, characterizes those polymers that possess high degrees of inter- and intra-molecular order in the solid state. Heat of fusion, a measure of crystallinity, greater than 60 J/g, alternatively at least 70 J/g, alternatively at least 80 J/g, as determined by DSC analysis, is preferred. The heat of fusion is dependent on the composition of the polypropylene. A propylene homopolymer will have a higher heat of fusion than a copolymer or blend of a homopolymer and copolymer.

Where the thermoplastic polymer matrix is polypropylene, the matrix can vary widely in composition. For example, substantially isotactic polypropylene homopolymer or propylene copolymer containing 10 weight percent or less of a comonomer can be used (i.e., at least 90% by weight propylene). Further, polypropylene segments may be part of graft or block copolymers having a sharp melting point above 110° C. and alternatively above 115° C. and alternatively above 130° C., characteristic of the stereoregular propylene sequences. The continuous phase matrix may be a combination of homopolypropylene, and/or random, and/or block copolymers as described herein. When the matrix is a random copolymer, the percentage of the copolymerized alpha-olefin in the copolymer is, in general, up to 9% by weight, alternatively 0.5% to 8% by weight, alternatively 2% to 6% by weight. The preferred alpha-olefins contain 2 or from 4 to 12 carbon atoms. One, two or more alpha-olefins can be copolymerized with propylene.

The Second Polymer

The dispersed second polymer phase of the heterogeneous polymer blend of the invention is generally an elastomeric copolymer and is polymerized and also cross-linked in the presence of the first polymer. The second polymer is generally an amorphous or low crystallinity (having a crystallinity of less than 20%) polymer and in particular may include any elastomer or mixture thereof that is capable of forming a cross-linked system during the polymerization. Some non-limiting examples of these elastomers include olefin copolymers, butyl rubber, styrene-butadiene copolymer rubber, butadiene rubber, acrylonitrile rubber, halogenated rubber such as brominated and chlorinated isobutylene-isoprene copolymer rubber, butadiene-styrene-vinyl pyridine rubber, urethane rubber, polyisoprene rubber, epichlolorohydrin terpolymer rubber, and polychloroprene. The second polymer of the heterogeneous polymer blend of the invention can also comprise atactic polymers such as atactic polypropylene. The preferred second polymers are elastomeric olefin copolymers.

Suitable elastomeric copolymers for use in the present invention are rubbery copolymers produced by copolymerizing two or more alpha olefins with at least one polyene, normally a diene. More typically, the elastomeric component is a copolymer of ethylene with at least one alpha-olefin monomer, and at least one diene monomer. The alpha-olefins may include, but are not limited to, C₃ to C₂₀ alpha-olefins, such as propylene, butene-1, hexene-1, 4-methyl-1 pentene, octene-1, decene-1, or combinations thereof. The preferred alpha-olefins are propylene, hexene-1, octene-1 or combinations thereof. Thus, for example, the second polymer can be an ethylene-propylene-diene (commonly called “EPDM”). Typically, the second polymer contains at least 15 wt % of the C₃ to C₂₀ olefin and at least 0.0001 wt % of the diene.

In one embodiment, the polyene has at least two unsaturated bonds that can readily be incorporated into polymers to form cross-linked polymers. Examples of such polyenes include α,ω-dienes (such as butadiene, 1,4-pentadiene, 1,5-hexadiene, 1,6-heptadiene, 1,7-octadiene, 1,8-nonadiene, 1,9-decadiene, 1.10-undecadiene, 1,11-dodecadiene, 1,12-tridecadiene, and 1,13-tetradecadiene) and certain multi-ring alicyclic fused and bridged ring dienes (such as tetrahydroindene; norbomdiene; methyl-tetrahydroindene; dicyclopentadiene; bicyclo-(2.2.1)-hepta-2,5-diene; and alkenyl-, alkylidene-, cycloalkenyl-, and cylcoalkyliene norbornenes [including, e.g., 5-methylene-2-norbornene, 5-ethylidene-2-norbornene, 5-propenyl-2-norbornene, 5-isopropylidene-2-norbornene, 5-(4-cyclopentenyl)-2-norbornene, 5-cyclohexylidene-2-norbornene, and 5-vinyl-2-norbornene]).

In further embodiment, the polyene has at least two unsaturated bonds wherein one of the unsaturated bonds is readily incorporated into a polymer. The second bond may partially take part in polymerization to form cross-linked polymers but normally provides at least some unsaturated bonds in the polymer product suitable for subsequent functionalization (such as with maleic acid or maleic anhydride), curing or vulcanization in post polymerization processes. Examples of polyenes according to said further embodiment include, but are not limited to butadiene, pentadiene, hexadiene, heptadiene, octadiene, nonadiene, decadiene, undecadiene, dodecadiene, tridecadiene, tetradecadiene, pentadecadiene, hexadecadiene, heptadecadiene, octadecadiene, nonadecadiene, icosadiene, heneicosadiene, docosadiene, tricosadiene, tetracosadiene, pentacosadiene, hexacosadiene, heptacosadiene, octacosadiene, nonacosadiene, triacontadiene, and polybutadienes having a molecular weight (M_(w)) of less than 1000 g/mol. Examples of straight chain acyclic dienes include, but are not limited to 1,4-hexadiene and 1,6-octadiene. Examples of branched chain acyclic dienes include, but are not limited to 5-methyl-1,4-hexadiene, 3,7-dimethyl-1,6-octadiene, and 3,7-dimethyl-1,7-octadiene. Examples of single ring alicyclic dienes include, but are not limited to 1,4-cyclohexadiene, 1,5-cyclooctadiene, and 1,7-cyclododecadiene. Examples of multi-ring alicyclic fused and bridged ring dienes include, but are not limited to tetrahydroindene; norbornadiene; methyl-tetrahydroindene; dicyclopentadiene; bicyclo-(2.2.1)-hepta-2,5-diene; and alkenyl-, alkylidene-, cycloalkenyl-, and cylcoalkyliene norbornenes [including, e.g., 5-methylene-2-norbornene, 5-ethylidene-2-norbornene, 5-propenyl-2-norbornene, 5-isopropylidene-2-norbornene, 5-(4-cyclopentenyl)-2-norbornene, 5-cyclohexylidene-2-norbornene, and 5-vinyl-2-norbornene]. Examples of cycloalkenyl-substituted alkenes include, but are not limited to vinyl cyclohexene, allyl cyclohexene, vinyl cyclooctene, 4-vinyl cyclohexene, allyl cyclodecene, vinyl cyclododecene, and tetracyclo (A-11,12)-5,8-dodecene.

According to one aspect of the invention, during the second polymerization step to produce the elastomeric phase, it is believed that a distribution of cross-products are formed emanating principally from the grafting of the first thermoplastic polymer to the second elastomeric polymer. These hybrid cross-products, also known as branch-block copolymers, form when reactive intermediates from the first polymerization step cross-over into the second polymerization step and participate in the polymerization of the second polymer. The presence of branch-block copolymers is believed to influence the events occurring during the polymerization as well as product properties. The extent of influence depends on the population distribution of the branch-block copolymer fraction.

The amount of second polymer relative to the first polymer may vary widely depending on the nature of the polymers and the intended use of the final polymer blend. In particular, however, one advantage of the process of the invention is the ability to be able to produce a heterogeneous polymer blend in which the discrete particles of the second polymer comprise more than 50 wt %, such as more than 60 wt %, for example more than 70 wt % of the total heterogeneous polymer blend. For TPV applications, the weight ratio of the second polymer to the first polymer is generally from about 90:10 to about 50:50, more preferably from about 80:20 to about 60:40, and most preferably from about 75:25 to about 65:35. For TPO or impact copolymer applications, the weight ratio of the second polymer to the first polymer is generally from about 49:51 to about 10:90, more preferably from 35:65 to about 15:85.

Production of the Polymer Blend

According to the invention, the polymer composition is produced by a novel two-step process. In the first step, a crystalline thermoplastic polymer is produced by polymerizing at least one first monomer in one or more polymerization zones. The effluent from the first step is then fed into a second polymerization step where an elastomer is produced in the presence of the polymer produced in the first step. The elastomer is in-situ cross-linked, at least partially, in the second polymerization zone. After removal of the polymerization medium, the cross-linked elastomer forms finely dispersed particles embedded within the crystalline thermoplastic matrix.

In an alternative embodiment, the first step of polymerization is replaced with addition of pre-made crystalline thermoplastic polymer. The pre-made polymer can be produced in a separate system or can be a commercially available product. The crystalline thermoplastic polymer can be dissolved in a solvent and then added into a reaction medium for the second polymerization step. The crystalline thermoplastic polymer can be also ground into fine powder and then added into the reaction medium for the second polymerization step.

Any known polymerization process may be used to produce the thermoplastic polymer. For example, the polymer may be a propylene homopolymer obtained by homopolymerization of propylene in a single stage or multiple stage reactor. Copolymers may be obtained by copolymerizing propylene and an alpha-olefin having 2 or from 4 to 20 carbon atoms in a single stage or multiple stage reactor. Polymerization methods include high pressure, slurry, gas, bulk, suspension, supercritical, or solution phase, or a combination thereof, using a traditional Ziegler-Natta catalyst or a single-site, metallocene catalyst system, or combinations thereof including bimetallic (i.e, Z/N and/or metallocene) catalysts. Preferred catalysts are those capable of polymerizing a C₂ to C₂₀ olefin to produce a first polymer having at least 30% crystallinity and at least 0.01% terminal unsaturation. The catalysts can be in the form of a homogeneous solution, supported, or a combination thereof. Polymerization may be carried out by a continuous, a semi-continuous or batch process and may include use of chain transfer agents, scavengers, or other such additives as deemed applicable. By continuous is meant a system that operates (or is intended to operate) without interruption or cessation. For example a continuous process to produce a polymer would be one where the reactants are continually introduced into one or more reactors and polymer product is continually withdrawn.

Where the thermoplastic matrix comprises a polyolefin, such as a propylene polymer or copolymer, the polyolefin will generally be produced in the presence of a single site catalyst, preferably a metallocene catalyst, with an activator and optional scavenger. Preferred metallocene catalysts are those capable of polymerizing a C₂ to C₂₀ olefin to produce a first polymer having at least 30% crystallinity.

Preferred metallocene catalysts useful for producing the thermoplastic first polymer in the process of the invention are not narrowly defined but generally it is found that the most suitable are those in the generic class of bridged, substituted bis(cyclopentadienyl) metallocenes, specifically bridged, substituted bis(indenyl) metallocenes known to produce high molecular weight, high melting, highly isotactic propylene polymers. Particularly suitable catalysts are bridged bis-indenyl metallocene catalysts having a substituent on one or both of the 2- and 4- positions on each indenyl ring or those having a substituent on the 2-, 4-, and 7- positions on each indenyl ring. Generally speaking, those of the generic class disclosed in U.S. Pat. No. 5,770,753 (fully incorporated herein by reference) should be suitable, however, it has been found that the exact polymer obtained is dependent on the metallocene's specific substitution pattern, among other things. A specific list of useful catalyst compounds is found at WO 2004/026921 page 29 paragraph [00100] to page 66, line 4. In another embodiment, the catalyst compounds described at WO 2004/026921 page 66, paragraph [00103] to page 70, line 3 may also be used in the practice of this invention.

Particularly preferred are racemic metallocenes, such as rac-dimethylsiladiyl(2-isopropyl,4-phenylindenyl)₂ zirconium dichloride; rac-dimethylsiladiyl(2- isopropyl,4-[1-naphthyl]indenyl)₂ zirconium dichloride; rac-dimethylsiladiyl(2- isopropyl,4-[3,5-dimethylphenyl]indenyl)₂ zirconium dichloride; rac-dimethylsiladiyl(2-isopropyl,4-[ortho-methyl-phenyl]indenyl)₂ zirconium dichloride; rac-dimethylsilyl bis-(2-methyl, 4-phenylindenyl)zirconium dichoride, rac dimethylsiladlyl bis-(2-methyl, 4-napthylindenyl) zirconium dichloride, rac-dimethyl siladiyl(2-isopropyl, 4-[3,5 di-t-butyl-phenyl]indenyl)₂ zirconium dichloride; rac-dimethyl siladiyl(2-isopropyl, 4-[orthophenyl-phenyl]indenyl)₂ zirconium dichloride, rac-diphenylsiladiyl(2-methyl4-[1-naphthyl]indenyl)₂ zirconium dichloride and rac-biphenyl siladiyl(2-isopropyl, 4-[3,5 di-t-butyl-phenyl]indenyl)₂ zirconium dichloride. Alkylated variants of these metallocenes (e.g. di-methyl instead of dichloride) are also useful, particularly when combined with a non-coordinating anion type activator. These and other metallocene compositions are described in detail in U.S. Pat. Nos. 6,376,407, 6,376,408, 6,376,409, 6,376,410, 6,376,411, 6,376,412, 6,376,413, 6,376,627, 6,380,120, 6,380,121, 6,380,122, 6,380,123, 6,380,124, 6,380,330, 6,380,331, 6,380,334, 6,399,723 and 6,825,372.

The manner of activation of the catalyst used in the first polymerization step can vary. Alumoxane and preferably methyl alumoxane (MAO) can be used. Non-or weakly coordinating anion activators (NCA) may be obtained in any of the ways described in EP277004, EP426637. Activation generally is believed to involve abstraction of an anionic group such as the methyl group to form a metallocene cation, although according to some literature zwitterions may be produced. The NCA precursor can be an ion pair of a borate or aluminate in which the precursor cation is eliminated upon activation in some manner, e.g. trityl or ammonium derivatives of tetrakis pentafluorophenyl boron (See EP277004). The NCA precursor can be a neutral compound such as a borane, which is formed into a cation by the abstraction of and incorporation of the anionic group abstracted from the metallocene (See EP426638).

The alumoxane activator may be utilized in an amount to provide a molar aluminum to metallocene ratio of from 1:1 to 20,000:1 or more. The non-coordinating compatible anion activator may be utilized in an amount to provide a molar ratio of metallocene compound to non-coordinating anion of 10:1 to 1:1.

Particularly useful activators include dimethylaniliniumtetrakis (pentafluorophenyl) borate and dimethyl anilinium tetrakis(heptafluoro-2-naphthyl) borate. For a more detailed description of useful activators please see WO 2004/026921 page 72, paragraph [00119] to page 81 paragraph [00151]. A list of particularly useful activators that can be used in the practice of this invention may be found at page 72, paragraph [00177] to page 74, paragraph [00178] of WO 2004/046214.

Preferably, the first polymerization step is conducted in a continuous, stirred tank reactor. Tubular reactors equipped with the hardware to introduce feeds, catalysts and cross-linking agents in staged manner can also be used. Generally, polymerization reactors are agitated (stirred) to reduce or avoid concentration gradients. Reaction environments include the case where the monomer(s) acts as diluent or solvent as well as the case where a liquid hydrocarbon is used as diluent or solvent. Preferred hydrocarbon liquids include both aliphatic and aromatic fluids such as desulphurized light virgin naphtha and alkanes, such as propane, isobutane, mixed butanes, hexane, pentane, isopentane, cyclohexane, isooctane, and octane. In an alternate embodiment a perfluorocarbon or hydrofluorocarbon is used as the solvent or diluent.

Suitable conditions for the first polymerization step include a temperature from about 50 to about 250° C., preferably from about 50 to about 150° C., more preferably from about 70 to about 150° C. and a pressure of 0.1 MPa or more, preferably 2 MPa or more. The upper pressure limit is not critically constrained but is typically 200 MPa or less, preferably, 120 MPa or less, except when operating ins supercritical phase then the pressure and temperature are above the critical point of the reaction media in question (typically over 95° C. and 4.6 MPa for propylene polymerizations). For more information on running supercritical polymerizations, please see WO 2004/026921. Temperature control in the reactor is generally obtained by balancing the heat of polymerization with reactor cooling via reactor jackets or cooling coils, auto refrigeration, pre-chilled feeds, vaporization of liquid medium (diluent, monomers or solvent) or combinations of all three. Adiabatic reactors with pre-chilled feeds may also be used.

In the second polymerization step, some or all of the first polymer formed in the first polymerization step are contacted with at least one second monomer, typically ethylene and a C₃ to C₂₀ olefin, and at least one cross-linking agent, typically a diene, under conditions sufficient to polymerize the second monomer(s) to produce the second polymer and also cross-link said second polymer. As a result of the cross-linking that occurs with the second polymerization step, the product of the second polymerization step contains at least a fraction which is insoluble in xylene. Preferably, the amount of said xylene insoluble fraction by weight of the second polymer, also referred to herein as the degree of cross-link of the second polymer, is at least 4%, such as at least 10%, such as at least 20%, such as at least 40%, such as at least 50%.

Any known polymerization process, including solution, suspension, slurry, supercritical and gas phase polymerization processes, and any known polymerization catalyst can be used to produce the second polymer component. Generally, the catalyst used to produce the second polymer component should be capable of polymerizing bulky monomers and also be capable of producing a polymer having an Mw of 20,000 or more and a crystallinity of less than 20%.

In one embodiment, the catalyst employed to produce the second polymer component is the same as, or is compatible with, the catalyst used to produce the thermoplastic matrix. In such a case, the first and second polymerization zones can be in a multiple-zone reactor, or separate, series-connected reactors, with the entire effluent from the first polymerization zone, including any active catalyst, being transferred to the second polymerization zone. Additional catalyst can then be added, as necessary to the second polymerization zone. In a particularly preferred embodiment, the process of the invention is conducted in two or more series-connected, continuous flow, stirred tank or tubular reactors using metallocene catalysts.

In another embodiment, catalyst quenching is applied between the two polymerization zones and a separate catalyst is introduced in the second reaction zone to produce the elastomer component. Catalyst quenching agents (such as air or an alcohol) may be introduced into the effluent from the first polymerization zone right after the reactor exit to deactivate the catalyst used for the first polymerization. Scavenger may be useful and can be fed into the effluent downstream of the catalyst quenching agent injection point or the second polymerization zone.

Where a separate catalyst is used to produce the elastomeric second polymer, this is conveniently one of, or a mixture of, metallocene compounds of either or both of the following types:

-   -   1) Cyclopentadienyl (Cp) complexes which have two Cp ring         systems for ligands. The Cp ligands form a sandwich complex with         the metal and can be free to rotate (unbridged) or locked into a         rigid configuration through a bridging group. The Cp ring         ligands can be like or unlike, unsubstituted, substituted, or a         derivative thereof such as a heterocyclic ring system which may         be substituted, and the substitutions can be fused to form other         saturated or unsaturated rings systems such as         tetrahydroindenyl, indenyl, or fluorenyl ring systems. These         cyclopentadienyl complexes are represented by the formula         (Cp¹R¹ _(m))R³ _(n)(Cp²R² _(p))MX_(q)     -    wherein Cp¹ of ligand (Cp¹ R¹ _(m))and Cp² of ligand (Cp² R²         _(p)) are the same or different cyclopentadienyl rings, R¹ and         R² each is, independently, a halogen or a hydrocarbyl,         halocarbyl, hydrocarbyl-substituted organometalloid or         halocarbyl-substituted organometalloid group containing up to         about 20 carbon atoms, m is 0, 1, 2, 3, 4, or 5, p is 0, 1, 2,         3, 4 or 5, and two R¹ and/or R² substituents on adjacent carbon         atoms of the cyclopentadienyl ring associated there with can be         joined together to form a ring containing from 4 to about 20         carbon atoms, R³ is a bridging group, n is the number of atoms         in the direct chain between the two ligands and is 0, 1, 2, 3,         4, 5, 6, 7, or 8, preferably 0, 1, 2, or 3, M is a transition         metal having a valence of 3, 4, 5 or 6, preferably from Group 4,         5, or 6 of the Periodic Table of the Elements and is preferably         in its highest oxidation state, each X is a non-cyclopentadienyl         ligand and is, independently, a halogen or a hydrocarbyl,         oxyhydrocarbyl, halocarbyl, hydrocarbyl-substituted         organometalloid, oxyhydrocarbyl-substituted organometalloid or         halocarbyl-substituted organometalloid group containing up to         about 20 carbon atoms, q is equal to the valence of M minus 2.     -   2) Monocyclopentadienyl complexes which have only one Cp ring         system as a ligand. The Cp ligand forms a half-sandwich complex         with the metal and can be free to rotate (unbridged) or locked         into a rigid configuration through a bridging group to a         heteroatom-containing ligand. The Cp ring ligand can be         unsubstituted, substituted, or a derivative thereof such as a         heterocyclic ring system which may be substituted, and the         substitutions can be fused to form other saturated or         unsaturated rings systems such as tetrahydroindenyl, indenyl, or         fluorenyl ring systems. The heteroatom containing ligand is         bound to both the metal and optionally to the Cp ligand through         the bridging group. The heteroatom itself is an atom with a         coordination number of three from Group 15 or 16 of the periodic         table of the elements. These mono-cyclopentadienyl complexes are         represented by the formula         (Cp¹R¹ _(m))R³ _(n)(Y R²)MX_(s)     -    wherein R¹ is, each independently, a halogen or a hydrocarbyl,         halocarbyl, hydrocarbyl-substituted organometalloid or         halocarbyl-substituted organometalloid group containing up to         about 20 carbon atoms, m is 0, 1, 2, 3, 4 or 5, and two R¹         substituents on adjacent carbon atoms of the cyclopentadienyl         ring associated therewith can be joined together to form a ring         containing from 4 to about 20 carbon atoms, R³ is a bridging         group, n is 0, 1, 2 or 3, M is a transition metal having a         valence of from 3, 4, 5, or 6, preferably from Group 4, 5, or 6         of the Periodic Table of the Elements and is preferably in its         highest oxidation state, Y is a heteroatom containing group in         which the heteroatom is an element with a coordination number of         three from Group 15 or a coordination number of two from Group         16 preferably nitrogen, phosphorous, oxygen, or sulfur, R² is a         radical selected independently from the group consisting of C₁         to C₂₀ hydrocarbon radicals, substituted C₁ to C₂₀ hydrocarbon         radicals, wherein one or more hydrogen atoms is replaced with a         halogen atom, and when Y is three coordinate and unbridged there         may be two R₂ groups on Y each independently a radical selected         from a group consisting of C₁ to C₂₀ hydrocarbon radicals,         substituted C₁ to C₂₀ hydrocarbon radicals, wherein one or more         hydrogen atoms is replaced with a halogen atom, and each X is a         non-cyclopentadienyl ligand and is, independently, a halogen or         a hydrocarbyl, oxyhydrocarbyl, halocarbyl,         hydrocarbyl-substituted organometalloid,         oxyhydrocarbyl-substituted organometalloid or         halocarbyl-substituted organometalloid group containing up to         about 20 carbon atoms, s is equal to the valence of M minus 2;         and Cp¹ is a Cp ring.

Examples of suitable biscyclopentadienyl metallocenes of the type described in Group 1 above for the invention are disclosed in U.S. Pat. Nos. 5,324,800; 5,198,401; 5,278,119; 5,387,568; 5,120,867; 5,017,714; 4,871,705; 4,542,199; 4,752,597; 5,132,262; 5,391,629; 5,243,001; 5,278,264; 5,296,434; and 5,304,614, all of which are incorporated by reference herein.

Illustrative, but not limiting examples of preferred biscyclopentadienyl metallocenes of the type described in Group 1 above for the invention are the racemic isomers of:

-   -   μ-(CH₃)₂Si(indenyl)₂M(Cl)₂     -   μ-(CH₃)₂Si(indenyl)₂M(CH₃)₂     -   μ-(CH₃)₂Si(tetrahydroindenyl)₂M(Cl)₂     -   μ-(CH₃)₂Si(tetrahydroindenyl)₂M(CH₃)₂     -   μ-(CH₃)₂Si(indenyl)₂M(CH₂CH₃)₂     -   μ-(C₆H₅)₂C(indenyl)₂M(CH₃)₂         wherein M is chosen from a group consisting of Zr and Hf.

Examples of suitable unsymmetrical cyclopentadienyl metallocenes of the type described in Group 1 above for the invention are disclosed in U.S. Pat. Nos. 4,892,851; 5,334,677; 5,416,228; and 5,449,651; and are described in publication J Am. Chem. Soc. 1988, 110, 6255, all of which are incorporated by reference herein.

Illustrative, but not limiting examples of preferred unsymmetrical cyclopentadienyl metallocenes of the type described in Group 1 above for the invention are:

-   -   μ-(C₆H₅)₂C(cyclopentadienyl)(fluorenyl)M(R)₂     -   μ-(C₆H₅)₂C(3-methylcyclopentadienyl)(fluorenyl)M(R)₂     -   μ-(CH₃)₂C(cyclopentadienyl)(fluorenyl)M(R)₂     -   μ-(C₆H₅)₂C(cyclopentadienyl)(2-methylindenyl)M(R)₂     -   μ-(C₆H₅)₂C(3-methylcyclopentadienyl)(2-methylindenyl)M(R)₂     -   μ-(p-triethylsilylphenyl)₂C(cyclopentadienyl)(3,8-di-t-butylfluorenyl)M(R)₂     -   μ-(C₆H₅)₂C(cyclopentadienyl)(2,7-dimethylindenyl)M(R)₂     -   μ-(CH₃)₂C(cyclopentadienyl)(2,7-dimethylindenyl)M(R)₂.         wherein M is chosen from the group consisting of Zr and Hf and R         is chosen from the group consisting of Cl and CH₃.

Examples of suitable monocyclopentadienyl metallocenes of the type described in group 2 above for the invention are disclosed in U.S. Pat. Nos. 5,026,798; 5,057,475; 5,350,723; 5,264,405; 5,055,438 and are described in publication WO 96/002244, all of which are incorporated by reference herein.

Illustrative, but not limiting examples of preferred monocyclopentadienyl metallocenes of the type described in group 2 above for the invention are:

-   -   μ-(CH₃)₂Si(cyclopentadienyl)(1-adamantylamido)M(R)₂     -   μ-(CH₃)₂Si(3-tertbutylcyclopentadienyl)(1-adamantylamido)M(R)₂     -   μ-(CH₃)₂Si(tetramethylcyclopentadienyl)(1-adamantylamido)M(R)₂     -   μ-(CH₃)₂C(tetramethylcyclopentadienyl)(1-adamantylamido)M(R)₂     -   μ-(CH₃)₂Si(tetramethylcyclopentadienyl)(1-tertbutylamido)M(R)₂     -   μ-(CH₃)₂Si(fluorenyl)(1-tertbutylamido)M(R)₂     -   μ-(CH₃)₂Si(tetramethylcyclopentadienyl)(1-cyclododecylamido)M(R)₂     -   μ-(CH₃)₂C(tetramethylcyclopentadienyl)(1-cyclododecylamido)M(R)₂         wherein M is selected from a group consisting of Ti, Zr, and Hf         and wherein R is selected from Cl and CH₃.

Another class of organometallic complexes that are useful catalysts for producing the second polymer component are those with diimido ligand systems such as those described in WO 96/23010 assigned to Du Pont. These catalytic polymerization compounds are incorporated here by reference.

In a preferred processing mode, the conditions in the second polymerization zone are arranged not only to copolymerize the elastomer monomers with the bifunctional monomer, such as a diene, but also to cause at least partial cross-linking of resultant elastomer. Typical conditions in the second polymerization zone include a temperature of about 10° C. to about 250° C. and a pressure of about 0.1 MPa to about 200 MPa.

The second polymer, which is at least partially cross-linked in the copolymerization reaction of olefins and dienes, may be prepared by solution, suspension or slurry polymerization of the olefins and diene under conditions in which the catalyst site remains relatively insoluble and/or immobile so that the polymer chains are rapidly immobilized following their formation. Such immobilization is affected, for example, by (1) using a solid, insoluble catalyst, (2) maintaining the polymerization below the crystalline melting point of thermoplastic polymers made in the first step and (3) using low solvency solvent such as a fluorinated hydrocarbon.

In a solution process, the uncrosslinked second polymers are preferably dissolved (or are soluble) in the polymerization media. The second polymers are then phase separated from the reaction media to form micro-particles when the polymers are cross-linked. This in-situ cross-link and phase separation facilitates the process to produce polymers of high molecular weight.

By selecting the catalysts, the polymerization reaction conditions, and/or by introducing a diene modifier, some molecules of the first polymer(s) and the second polymer(s) can be linked together to produce branch-block structures. While not wishing to be bound by theory, the branch-block copolymer is believed to comprise an amorphous backbone having crystalline side chains originating from the first polymer.

To effectively incorporate the polymer chains of the first polymer into the growing chains of the second polymer, it is preferable that the first polymerization step produces macromonomers having reactive termini, such as vinyl end groups. By macromonomers having reactive termini is meant a polymer having twelve or more carbon atoms (preferably 20 or more, more preferably 30 or more, more preferably between 12 and 8000 carbon atoms) and having a vinyl, vinylidene, vinylene or other terminal group that can be polymerized into a growing polymer chain. By capable of polymerizing macromonomer having reactive termini is meant a catalyst component that can incorporate a macromonomer (which tend to be molecules larger than a typical single monomer such as ethylene or propylene), having reactive termini into a growing polymer chain. Vinyl terminated chains are generally more reactive than vinylene or vinylidene terminated chains. Generally, it is desirable that the first polymerization step produces a first polymer having at least 0.01% terminal unsaturation.

Optionally the thermoplastic first polymers are copolymers of one or more alpha olefins and one or more of monomers having at least two olefinically unsaturated bonds. Both of these unsaturated bonds are suitable for and readily incorporated into a growing polymer chain by coordination polymerization using either the first or second catalyst systems independently such that one double bond is incorporated into the first polymer segments while another double bond is incorporated into the second elastomeric polymer segments for form a branched block copolymer. In a preferred embodiment these monomers having at least two olefinically unsaturated bonds are di-olefins, preferably di-vinyl monomers.

A polymer can be recovered from the effluent of either the first polymerization step or the second polymerization step by separating the polymer from other constituents of the effluent using conventional separation means. For example, polymer can be recovered from either effluent by coagulation with a non-solvent such as isopropyl alcohol, acetone, or n-butyl alcohol, or the polymer can be recovered by stripping the solvent or other media with heat or steam. One or more conventional additives such as antioxidants can be incorporated in the polymer during the recovery procedure. Possible antioxidants include phenyl-beta-naphthylamine; di-tert-butylhydroquinone, triphenyl phosphate, heptylated diphenylamine, 2,2′-methylene-bis (4-methyl-6-tert-butyl)phenol, and 2,2,4-trimethyl-6-phenyl-1,2-dihydroquinoline. Other methods of recovery such as by the use of lower critical solution temperature (LCST) followed by devolatilization are also envisioned. The catalyst may be deactivated as part of the separation procedure to reduce or eliminate further uncontrolled polymerization downstream the polymer recovery processes. Deactivation may be effected by the mixing with suitable polar substances such as water, whose residual effect following recycle can be counteracted by suitable sieves or scavenging systems.

Properties of the Polymer Blend

By virtue of the novel polymerization process used in its production, the heterogeneous polymer blend of the invention not only comprises particles of the second polymer dispersed within a matrix of the first thermoplastic polymer but also at least a portion the dispersed phase is cross-linked and preferably comprises a hybrid species of said first and second polymers having characteristics of the first and second polymers such as a melting temperature, preferably of at least 100° C., in the xylene insoluble fraction. In addition, it is found that the particles of the second polymer tend be more evenly distributed and significantly smaller, typically having an average diameter of less than 1 micron, than products obtained by conventional reactive extrusion techniques.

In addition, since at least some cross-linking of the dispersed phase occurs during the second polymerization step, rather than all the cross-linking being effected in a subsequent dynamic extrusion step, the dispersed phase of the heterogeneous polymer blend of the invention comprises at least a fraction which is insoluble in xylene and which is substantially free of the curatives normally added to polymers blends to effect cross-linking during post-polymerization, dynamic extrusion. By substantially free is meant that the dispersed phase contains less than 10,000 ppm, such as less than 1,000 ppm, such as less than 1000 ppm, such as less than 10 ppm, of a curative.

Polymers with bimodal distributions of molecular weight and composition can be produced by the polymerization process of the invention, by, for example, controlling the polymerization conditions in the first and the second polymerization zones and selecting the catalysts for the first and the second polymerizations, such as by using multiple catalysts in each polymerization zone. Some of the polymer chains produced in the first polymerization zone are still live in the second polymerization zone. The polymer chains so produced in the second polymerization zone contain crystalline polymer segments and amorphous polymer segments and form blocky structures. The blocky compositions have characteristics of both the first and second polymers.

Generally, olefins are present in the elastomeric dispersed phase of the heterogeneous polymer blend of the invention at levels from about 95 to about 99.99 wt %, whereas the diene content of the elastomeric copolymer is from about 0.01 wt % to about 5 wt %. But specific embodiments can have a variety of diene contents. Some embodiments have two or more different olefin units in the elastomeric component, with at least one monomer being selected from ethylene, propylene and C₄ to C₂₀ alpha-olefins. Typically, said at least one monomer unit comprises ethylene and a further monomer is selected from propylene and C₄ to C₁₂ alpha-olefins, especially propylene. These embodiments typically have one olefin present in amounts of from 12 to 88 wt %, for example from 30 to 70 wt %, of the copolymer whereas the other olefin is present in amounts of from 88 to 12 wt %, for example from 70 to 30 wt %, of the copolymer.

Still more desirably, the copolymer includes: ethylene units in the range from 12 wt % to 88 wt % of the copolymer; propylene or other α-olefin(s) units in the range from 88 wt % to 12 wt %, desirably ethylene units in the range from 30 to 70 wt % and propylene or other α-olefin(s) units in the range from 70 to 30 wt %; more desirably ethylene units in the range from 40 wt % to 60 wt % and propylene or other α-olefin(s) units in the range from 60 to 40 wt % of the copolymer.

The individual components of the heterogeneous polymer blend of the invention can readily be separated by solvent extraction. In a suitable solvent extraction regime, the blend, without undergoing any additional processing steps, is contacted with cyclohexane at 25° C. for 48 hours to dissolve the uncured and branched elastomeric components of the blend and then the remaining solids are refluxed at the boiling temperature of xylene for 24 hours with xylene to dissolve the continuous thermoplastic phase material. The remaining xylene insolubles comprise the cross-linked hybrid copolymers of the first and second polymers. These hybrid copolymers typically exhibit a melting temperature in excess of 100° C.

In one embodiment, the polymer blend described herein has a tensile strength at break (as measured by ISO 37 at 23° C.) of 0.5 MPa or more, alternatively 0.75 MPa or more, alternatively 1.0 MPa or more, alternatively 1.5 MPa or more, alternatively 2.0 MPa or more, alternatively 2.5 MPa or more, alternatively 3.0 MPa or more, alternatively 3.5 MPa or more.

In another embodiment, the polymer blend described herein has a Shore hardness of 30A to 90D, preferably 15A to 90D (as measured by ISO 868).

In another embodiment, the polymer blend described herein has an ultimate elongation (as measured by ISO 37) of 20% or more, preferably 30% or more, more preferably 40% or more.

In another embodiment, the polymer blend described herein has a compression set (as measured by ISO 815A) of 90% or less, preferably 70% or less, more preferably 50% or less, more preferably 30% or less, more preferably 10% or less.

In another embodiment, the polymer blend described herein has a tension set (as measured by ISO 2285) of 100% or less, preferably 80% or less, more preferably 60% or less, more preferably 20% or less, more preferably 5% or less, more preferably 1% or less.

In another embodiment, the polymer blend described herein has an oil swell (as measured by ASTM D471) of 500% or less, preferably 250% or less, more preferably 100% or less.

Additives

The heterogeneous polymer blend according to the invention may optionally contain reinforcing and non-reinforcing fillers, plasticizers, antioxidants, stabilizers, rubber processing oils, extender oils, lubricants, antiblocking agents, antistatic agents, waxes, foaming agents, pigments, flame retardants and other processing aids known in the rubber compounding art. Such additives may comprise up to about 70 weight percent, more preferably up to about 65 weight percent, of the total composition. Fillers and extenders which can be utilized include conventional inorganics such as calcium carbonate, clays, silica, talc, titanium dioxide, carbon black and the like. The rubber processing oils generally are paraffinic, naphthenic or aromatic oils derived from petroleum fractions. The oils are selected from those ordinarily used in conjunction with the specific rubber or rubber component present in the composition.

The additives such as fillers and oils can be introduced into the heterogeneous polymer blend during the polymerization in either the first polymerization zone or the second polymerization zone. The additives can be added into the effluent from the second polymerization zone and are preferably added into the polymer blend after removal of solvent or diluent through melt blending.

Additional polymers can also be added to form blends. In one or more embodiments, the additional polymers include thermoplastic resins. Exemplary thermoplastic resins include crystalline and crystallizable polyolefins. Also, suitable thermoplastic resins may include copolymers of polyolefins with styrene, such as a styrene-ethylene copolymer. In one or more embodiments, the thermoplastic resins are formed by polymerizing ethylene or α-olefins such as propylene, 1-butene, 1-hexene, 1-octene, 2-methyl-1-propene, 3-methyl-1-pentene, 4-methyl-1-pentene, 5-methyl-1-hexene, and mixtures thereof. Copolymers of ethylene and propylene and ethylene and propylene with another α-olefin such as 1-butene, 1-hexene, 1-octene, 2-methyl-1-propene, 3-methyl-1-pentene, 4-methyl-1-pentene, 5-methyl-1-hexene or mixtures thereof are also contemplated. Specifically included are homopolypropylene, impact, and random copolymers of propylene with ethylene or the higher α-olefins, described above, or with C₁₀-C₂₀ diolefins. Preferably, the homopolypropylene has a melting point of at least 130° C., for example at least 140° C. and preferably less than or equal to 160° C., a heat of fusion of at least 75 J/g, alternatively at least 80 J/g, as determined by DSC analysis, and weight average molecular weight (Mw) of at least 100,000, alternatively at least 500,000. Comonomer contents for these propylene copolymers will typically be from 1 to about 30% by weight of the polymer, for example, See U.S. Pat. Nos. 6,268,438, 6,288,171, and 6,245,856. Copolymers available under the tradename VISTAMAXX™ (ExxonMobil) are specifically included. Blends or mixtures of two or more polyolefin thermoplastics such as described herein, or with other polymeric modifiers, are also suitable in accordance with this invention. These homopolymers and copolymers may be synthesized by using an appropriate polymerization technique known in the art such as, but not limited to, the conventional Ziegler-Natta type polymerizations, and catalysis employing single-site organometallic catalysts including, but not limited to, metallocene catalysts.

Uses of the Polymer Blends

The heterogeneous polymer blends described herein may be shaped into desirable end use articles by any suitable means known in the art. They are particularly useful for making articles by blow molding, extrusion, injection molding, thermoforming, gas foaming, elasto-welding and compression molding techniques.

Thermoforming is a process of forming at least one pliable plastic sheet into a desired shape. An embodiment of a thermoforming sequence is described, however this should not be construed as limiting the thermoforming methods useful with the compositions of this invention. First, an extrudate film of the composition of this invention (and any other layers or materials) is placed on a shuttle rack to hold it during heating. The shuttle rack indexes into the oven which pre-heats the film before forming. Once the film is heated, the shuffle rack indexes back to the forming tool. The film is then vacuumed onto the forming tool to hold it in place and the forming tool is closed. The forming tool can be either “male” or “female” type tools. The tool stays closed to cool the film and the tool is then opened. The shaped laminate is then removed from the tool.

Thermoforming is accomplished by vacuum, positive air pressure, plug-assisted vacuum forming, or combinations and variations of these, once the sheet of material reaches thermoforming temperatures, typically of from 140° C. to 185° C. or higher. A pre-stretched bubble step is used, especially on large parts, to improve material distribution. In one embodiment, an articulating rack lifts the heated laminate towards a male forming tool, assisted by the application of a vacuum from orifices in the male forming tool. Once the laminate is firmly formed about the male forming tool, the thermoformed shaped laminate is then cooled, typically by blowers. Plug-assisted forming is generally used for small, deep drawn parts. Plug material, design, and timing can be critical to optimization of the process. Plugs made from insulating foam avoid premature quenching of the plastic. The plug shape is usually similar to the mold cavity, but smaller and without part detail. A round plug bottom will usually promote even material distribution and uniform side-wall thickness.

The shaped laminate is then cooled in the mold. Sufficient cooling to maintain a mold temperature of 30° C. to 65° C. is desirable. The part is below 90° C. to 100° C. before ejection in one embodiment. For the good behavior in thermoforming, the lowest melt flow rate polymers are desirable. The shaped laminate is then trimmed of excess laminate material.

Blow molding is another suitable forming means, which includes injection blow molding, multi-layer blow molding, extrusion blow molding, and stretch blow molding, and is especially suitable for substantially closed or hollow objects, such as, for example, gas tanks and other fluid containers. Blow molding is described in more detail in, for example, CONCISE ENCYCLOPEDIA OF POLYMER SCIENCE AND ENGINEERING 90-92 (Jacqueline I. Kroschwitz, ed., John Wiley & Sons 1990).

In yet another embodiment of the formation and shaping process, profile co-extrusion can be used. The profile co-extrusion process parameters are as above for the blow molding process, except the die temperatures (dual zone top and bottom) range from 150° C. to 235° C., the feed blocks are from 90° C. to 250° C., and the water cooling tank temperatures are from 10° C. to 40° C.

One embodiment of an injection molding process is described as follows. The shaped laminate is placed into the injection molding tool. The mold is closed and the substrate material is injected into the mold. The substrate material has a melt temperature between 200° C. and 300° C., such as between 215° C. and 250° C. and is injected into the mold at an injection speed of between 2 and 10 seconds. After injection, the material is packed or held at a predetermined time and pressure to make the part dimensionally and aesthetically correct. Typical time periods are from 5 to 25 seconds and pressures from 1,380 kPa to 10,400 kPa. The mold is cooled between 10° C. and 70° C. to cool the substrate. The temperature will depend on the desired gloss and appearance desired. Typical cooling time is from 10 to 30 seconds, depending on part on the thickness. Finally, the mold is opened and the shaped composite article ejected.

Likewise, molded articles may be fabricated by injecting molten polymer into a mold that shapes and solidifies the molten polymer into desirable geometry and thickness of molded articles. Sheet may be made either by extruding a substantially flat profile from a die, onto a chill roll, or alternatively by calendaring. Sheet will generally be considered to have a thickness of from 10 mils to 100 mils (254 μm to 2540 μm), although sheet may be substantially thicker. Tubing or pipe may be obtained by profile extrusion for uses in medical, potable water, land drainage applications or the like. The profile extrusion process involves the extrusion of molten polymer through a die. The extruded tubing or pipe is then solidified by chill water or cooling air into a continuous extruded articles. The tubing will generally be in the range of from 0.31 cm to 2.54 cm in outside diameter, and have a wall thickness of in the range of from 254 cm to 0.5 cm. The pipe will generally be in the range of from 2.54 cm to 254 cm in outside diameter, and have a wall thickness of in the range of from 0.5 cm to 15 cm. Sheet made from the products of an embodiment of a version of the present invention may be used to form containers. Such containers may be formed by thermoforming, solid phase pressure forming, stamping and other shaping techniques. Sheets may also be formed to cover floors or walls or other surfaces.

In an embodiment of the thermoforming process, the oven temperature is between 160° C. and 195° C., the time in the oven between 10 and 20 seconds, and the die temperature, typically a male die, between 10° C. and 71° C. The final thickness of the cooled (room temperature), shaped laminate is from 10 μm to 6000 μm in one embodiment, from 200 μm to 6000 μm in another embodiment, and from 250 μm to 3000 μm in yet another embodiment, and from 500 μm to 1550 μm in yet another embodiment, a desirable range being any combination of any upper thickness limit with any lower thickness limit.

In an embodiment of the injection molding process, wherein a substrate material is injection molded into a tool including the shaped laminate, the melt temperature of the substrate material is between 230° C. and 255° C. in one embodiment, and between 235° C. and 250° C. in another embodiment, the fill time from 2 to 10 seconds in one embodiment, from 2 to 8 seconds in another embodiment, and a tool temperature of from 25° C. to 65° C. in one embodiment, and from 27° C. and 60° C. in another embodiment. In a desirable embodiment, the substrate material is at a temperature that is hot enough to melt any tie-layer material or backing layer to achieve adhesion between the layers.

In yet another embodiment of the invention, the compositions of this invention may be secured to a substrate material using a blow molding operation. Blow molding is particularly useful in such applications as for making closed articles such as fuel tanks and other fluid containers, playground equipment, outdoor furniture and small enclosed structures. In one embodiment of this process, Compositions of this invention are extruded through a multi-layer head, followed by placement of the uncooled laminate into a parison in the mold. The mold, with either male or female patterns inside, is then closed and air is blown into the mold to form the part.

It will be understood by those skilled in the art that the steps outlined above may be varied, depending upon the desired result. For example, an extruded sheet of the compositions of this invention may be directly thermoformed or blow molded without cooling, thus skipping a cooling step. Other parameters may be varied as well in order to achieve a finished composite article having desirable features.

The thermoplastic elastomer blends of this invention are useful for making a variety of articles such as weather seals, hoses, belts, gaskets, moldings, boots, elastic fibers and like articles. Foamed end-use articles are also envisioned. More specifically, the blends of the invention are particularly useful for making vehicle parts, such as but not limited to, weather seals, brake parts including, but not limited to cups, coupling disks, diaphragm cups, boots such as constant velocity joints and rack and pinion joints, tubing, sealing gaskets, parts of hydraulically or pneumatically operated apparatus, o-rings, pistons, valves, valve seats, valve guides, and other elastomeric polymer based parts or elastomeric polymers combined with other materials such as metal, plastic combination materials which will be known to those of ordinary skill in the art. Also contemplated are transmission belts including V-belts, toothed belts with truncated ribs containing fabric faced V's, ground short fiber reinforced Vs or molded gum with short fiber flocked V's. The cross section of such belts and their number of ribs may vary with the final use of the belt, the type of market and the power to transmit. They also can be flat made of textile fabric reinforcement with frictioned outside faces. Vehicles contemplated where these parts will find application include, but are not limited to passenger autos, motorcycles, trucks, boats and other vehicular conveyances.

In alternate embodiments the invention also relates to:

-   -   1. A heterogeneous polymer blend comprising:         -   (a) a continuous phase comprising a thermoplastic first             polymer having a crystallinity of at least 30%; and         -   (b) a dispersed phase comprising particles of a second             polymer different from the first polymer dispersed in said             continuous phase, the second polymer having a crystallinity             of less than 20% and being at least partially cross-linked,             and the average particle size of the particles of the second             polymer being less than 1 micron.     -   2. The polymer blend of paragraph 1 wherein said thermoplastic         first polymer is a homopolymer of a C₂ to C₂₀ olefin.     -   3. The polymer blend of paragraph 1 or 2 wherein said         thermoplastic first polymer is a copolymer of a C₂ to C₂₀ olefin         with less than 15 wt % of at least one comonomer.     -   4. The polymer blend of paragraph 1, 2 or 3 wherein said         thermoplastic first polymer comprises a polymer of propylene.     -   5. The polymer blend of paragraph 1, 2, 3, or 4 wherein the         second polymer is produced from a plurality of comonomers         comprising at least one C₃ to C₂₀ olefin and at least one         polyene.     -   6. The polymer blend of paragraph 5 wherein said at least one         polyene has at least two polymerizable unsaturated groups.     -   7. The polymer blend of paragraph 5 or 6 wherein said plurality         of comonomers comprise propylene and ethylene.     -   8. The polymer blend of paragraph 1, 2, 3, 4, 5, 6, or 7 wherein         the average particle size of the particles of the second polymer         is between about 50 nanometers and about 0.5 microns.     -   9. The polymer blend of paragraph 1, 2, 3, 4, 5, 6, 7, or 8         wherein said dispersed phase comprises more than 50 wt % of the         total heterogeneous polymer blend.     -   10. A heterogeneous polymer blend comprising         -   (a) a continuous phase comprising a thermoplastic first             polymer having a crystallinity of at least 30%; and         -   (b) a dispersed phase comprising particles of a second             polymer different from the first polymer dispersed in said             continuous phase, the second polymer having a crystallinity             of less than 20% and being at least partially cross-linked,             and the average particle size of the particles of the second             polymer being less than 10 microns,     -   wherein said polymer blend is substantially free of processing         oil.     -   11. The polymer blend of paragraph 10 wherein said thermoplastic         first polymer is a homopolymer of a C₂ to C₂₀ olefin.     -   12. The polymer blend of paragraph 10 or 11 wherein said         thermoplastic first polymer is a copolymer of a C₂ to C₂₀ olefin         with less than 15 wt % of at least one comonomer.     -   13. The polymer blend of paragraph 10, 11, or 12 wherein the         second polymer is produced from a plurality of comonomers         comprising at least one C₃ to C₂₀ olefin and at least one         polyene.     -   14. The polymer blend of paragraph 10, 11, 12, or 13 wherein the         average particle size of the particles of the second polymer is         less than 1 micron.     -   15. The polymer blend of paragraph 10, 11, 12, 13, or 14 wherein         the average particle size of the particles of the second polymer         is between about 50 nanometers and about 0.5 microns.     -   16. A heterogeneous polymer blend comprising         -   (a) a continuous phase comprising a thermoplastic first             polymer that is at least partially crystalline; and         -   (b) a dispersed phase comprising particles of a second             polymer different from the first polymer dispersed in said             continuous phase, wherein said dispersed phase comprises at             least a fraction which is insoluble in xylene and which             comprises less than 2,500 ppm of a curative.     -   17. The polymer blend of paragraph 16 wherein said fraction         insoluble in xylene comprises less than 100 ppm of a curative.     -   18. The polymer blend of paragraph 16 or 17 wherein said         fraction insoluble in xylene comprises at least is at least 4%         of said dispersed phase.     -   19. A process for producing a heterogeneous polymer blend         (preferably the blends described in paragraphs 1 to 18)         comprising (a) a continuous phase comprising a thermoplastic         first polymer that is at least partially crystalline; and (b) a         dispersed phase comprising particles of a second polymer         different from the first polymer dispersed in said continuous         phase, the second polymer having a crystallinity less than that         of the first polymer and being at least partially cross-linked,         the process comprising:         -   (i) polymerizing at least one first monomer to produce a             thermoplastic first polymer that is at least partially             crystalline; and         -   (ii) contacting at least part of said first polymer with at             least one second monomer and at least one polyene under             conditions sufficient to polymerize said second monomer to             produce said second polymer and simultaneously cross-link             said second polymer such that the dispersed phase produced             by said contacting (ii) comprises at least a fraction which             is insoluble in xylene.     -   20. The process of paragraph 19 wherein said polymerizing (i) is         conducted in the presence of a catalyst and said contacting (ii)         is conducted in the presence of the same catalyst.     -   21. The process of paragraph 19 or 20 wherein said         polymerizing (i) is conducted in the presence of a first         catalyst and said contacting (ii) is conducted in the presence         of a second catalyst different from the first catalyst.     -   22. A process for producing a heterogeneous polymer blend (such         as the blends of paragraphs 1-18), the process comprising:         -   (a) selecting a catalyst capable of polymerizing a C₂ to C₂₀             olefin to produce a first polymer having at least 30%             crystallinity;         -   (b) contacting said catalyst with one or more C₂ to C₂₀             olefins at a temperature of at least 50° C. to produce a             first polymer having at least 30% crystallinity;         -   (c) contacting said first polymer and said catalyst with at             least one C₃ to C₂₀ olefin and at least one polyene under             conditions sufficient to polymerize said at least one C₃ to             C₂₀ olefin to produce a second polymer and simultaneously             cross-link said second polymer, whereby the product of said             contacting (c) is a heterogeneous polymer blend comprising a             continuous phase of the first polymer having at least 30%             crystallinity and a discontinuous phase of particles of said             second polymer having an average particle size less than 10             microns, said second polymer being at least partially             cross-linked and comprising at least 15 wt % of said C₃ to             C₂₀ olefin and at least 0.0001 wt % of said polyene.     -   23. The process of paragraph 22 wherein the first polymer         produced in said contacting (b) has at least 0.01% terminal         unsaturation.     -   24. The process of paragraph 22 or 23 wherein said C₂ to C₂₀         olefin comprises propylene.     -   25. The process of paragraph 22, 23 or 24 wherein said first         polymer is contacted with ethylene together with said at least         one C₃ to C₂₀ olefin and said at least one polyene in said         contacting (c).     -   26. The process of paragraph 22, 23, 24 or 25 wherein said         polyene has at least two polymerizable unsaturated groups.     -   27. The process of paragraph 22, 23, 24, 25, or 26 wherein said         catalyst selected in (a) is a single site catalyst comprising at         least one catalyst component and at least one activator.     -   28. The process of paragraph 27 wherein said catalyst component         is a bridged bis-indenyl metallocene catalyst having a         substituent on one or both of the 2- and 4- positions on each         indenyl ring.     -   29. A process for producing a heterogeneous polymer blend (such         as the blends of paragraphs 1 to 18), the process comprising:         -   (a) selecting a catalyst capable of polymerizing a C₂ to C₂₀             olefin to produce a first polymer having at least 30%             crystallinity;         -   (b) contacting said catalyst with one or more C₂ to C₂₀             olefins at a temperature of at least 50° C. to produce a             first polymer having at least 30% crystallinity;         -   (c) contacting said first polymer together with at least one             C₃ to C₂₀ olefin and at least one polyene with a catalyst             capable of polymerizing bulky monomers under conditions             sufficient to polymerize said at least one C₃ to C₂₀ olefin             to produce a second polymer and simultaneously cross-link             said second polymer, whereby the product of said             contacting (c) is a heterogeneous polymer blend comprising a             continuous phase of the first polymer having at least 30%             crystallinity and a discontinuous phase of particles of said             second polymer having an average particle size less than 3             microns, said second polymer being at least partially             cross-linked and comprising at least 15 wt % of said C₃ to             C₂₀ olefin and at least 0.0001 wt % of said polyene.     -   30. The process of paragraph 29 wherein the first polymer         produced in said contacting (b) has at least 0.1% terminal         unsaturation.     -   31. The process of paragraph 29 or 30 wherein said C₂ to C₂₀         olefin comprises propylene.     -   32. The process of paragraph 29, 30 or 31 wherein said first         polymer is contacted with ethylene together with said at least         one C₃ to C₂₀ olefin and said at least one polyene in said         contacting (c).     -   33. The process of paragraph 29, 30, 31, or 32 wherein said         polyene has at least two polymerizable unsaturated groups.     -   34. The process of paragraph 29, 30, 31, 32, or 33 wherein the         particles of said second polymer blend produced in step (c),         prior to any subsequent curing step, have a melting temperature         of at least 100° C.     -   35. The process of paragraph 29, 30, 31, 32, 33, or 34 wherein         the catalyst selected in (a) is different from the catalyst         employed in said contacting (c).

EXAMPLES

The invention will now be more particularly described with reference to the Examples and the accompanying drawings.

In the Examples, molecular weights (number average molecular weight (Mn), weight average molecular weight (Mw), and z-average molecular weight (Mz)) were determined using a Waters 150 Size Exclusion Chromatograph (SEC) equipped with a differential refractive index detector (DRI), an online low angle light scattering (LALLS) detector and a viscometer (VIS). The details of these detectors as well as their calibrations have been described by, for example, T. Sun, P. Brant, R. R. Chance, and W. W. Graessley, in Macromolecules, Volume 34, Number 19, 6812-6820, (2001), incorporated herein by reference. Solvent for the SEC experiment was prepared by adding 6 grams of butylated hydroxy toluene (BHT) as an antioxidant to a 4 liter bottle of 1,2,4 Trichlorobenzene (TCB) (Aldrich Reagent grade) and waiting for the BHT to solubilize. The TCB mixture was then filtered through a 0.7 micron glass pre-filter and subsequently through a 0.1 micron Teflon filter. There was an additional online 0.7 micron glass pre-filter/0.22 micron Teflon filter assembly between the high pressure pump and SEC columns. The TCB was then degassed with an online degasser (Phenomenex, Model DG-4000) before entering the SEC. Polymer solutions were prepared by placing dry polymer in a glass container, adding the desired amount of TCB, then heating the mixture at 160° C. with continuous agitation for about 2 hours. All quantities were measured gravimetrically. The TCB densities used to express the polymer concentration in mass/volume units were 1.463 g/ml at room temperature and 1.324 g/ml at 135° C. The injection concentration ranged from 1.0 to 2.0 mg/ml, with lower concentrations being used for higher molecular weight samples.

The branching index in the Examples was measured using SEC with an on-line viscometer (SEC-VIS) and is reported as g′ at each molecular weight in the SEC trace. The branching index g′ is defined as: $g^{\prime} = \frac{\eta_{b}}{\eta_{l}}$ where η_(b) is the intrinsic viscosity of the branched polymer and η₁ is the intrinsic viscosity of a linear polymer of the same viscosity-averaged molecular weight (M_(v)) as the branched polymer. η₁=KM_(v) ^(α), K and α were measured values for linear polymers and should be obtained on the same SEC-DRI-LS-VIS instrument as the one used for branching index measurement. For polypropylene samples presented in this invention, K=0.0002288 and α=0.705 were used. The SEC-DRI-LS-VIS method obviates the need to correct for polydispersities, since the intrinsic viscosity and the molecular weight were measured at individual elution volumes, which arguably contain narrowly dispersed polymer. Linear polymers selected as standards for comparison should be of the same viscosity average molecular weight, monomer content and composition distribution. Linear character for polymer containing C2 to C10 monomers is confirmed by Carbon-13 NMR using the method of Randall (Rev. Macromol. Chem. Phys., C29 (2&3), p. 285-297). Linear character for C11 and above monomers is confirmed by GPC analysis using a MALLS detector. For example, for a copolymer of propylene, the NMR should not indicate branching greater than that of the co-monomer (i.e. if the comonomer is butene, branches of greater than two carbons should not be present). For a homopolymer of propylene, the GPC should not show branches of more than one carbon atom. When a linear standard is desired for a polymer where the comonomer is C9 or more, one can refer to T. Sun, P. Brant, R. R. Chance, and W. W. Graessley, Macromolecules, Volume 34, Number 19, 6812-6820, (2001) for protocols on determining standards for those polymers. In the case of syndiotactic polymers, the standard should have a comparable amount of syndiotacticty as measured by Carbon 13 NMR. The viscosity averaged g′ was calculated using the following equation: $g_{vis}^{\prime} = \frac{\sum{C_{i}\left\lbrack \eta_{i} \right\rbrack}_{b}}{\sum{C_{i}{KM}_{i}^{\alpha}}}$

Where C_(i) is the polymer concentration in the slice i in the polymer peak, and [η_(i)]_(b) is the viscosity of the branched polymer in slice i of the polymer peak, and M_(i) is the weight averaged molecular weight in slice i of the polymer peak measured by light scattering, K and α are as defined above.

Peak melting point (Tm) and peak crystallization temperature (Tc) were determined using the following procedure according to ASTM E 794-85. Crystallinity was calculated using heat of fusion determined using ASTM D 3417-99. Differential scanning calorimetric (DSC) data were obtained using a TA Instruments model Q100 machine or a Perkin-Elmer DSC-7. Samples weighing approximately 5-10 mg were sealed in aluminum sample pans. The DSC data were recorded by first cooling the sample to −100° C. and then gradually heating it to 200° C. at a rate of 10° C./minute. The sample was kept at 200° C. for 5 minutes before a second cooling-heating cycle was applied. Both the first and second cycle thermal events were recorded. Areas under the melting curves were measured and used to determine the heat of fusion and the degree of crystallinity. The percent crystallinity is calculated using the formula, [area under the curve (Joules/gram)/B (Joules/gram)]*100, where B is the heat of fusion for the homopolymer of the major monomer component. These values for B were obtained from the Polymer Handbook, Fourth Edition, published by John Wiley and Sons, New York 1999. A value of 189 J/g (B) was used as the heat of fusion for 100% crystalline polypropylene. A value of 290 J/g is used for the heat of fusion for 100% crystalline polyethylene. For polymers displaying multiple cooling and melting peaks, all the peak crystallization temperatures and peaks melting temperatures were reported. The heat of fusion for each melting peak was calculated individually.

The glass transition temperature (Tg) was measured by ASTM E 1356 using a TA Instruments model Q100 machine.

Morphology data were obtained using an Atomic Force Microscope (AFM) in tapping phase. All specimens were analyzed within 8 hours after cryofacing to prevent specimen relaxation. During cryofacing, the specimens were cooled to −130° C. and cut with diamond knives in a Reichert cryogenic microtome. They were then stored in a dissector under flowing dry nitrogen gas to warm up to ambient temperatures without condensation being formed. Finally, the faced specimens were mounted in a miniature steel vise for AFM analysis. The AFM measurements were performed in air on a NanoScope Dimension 3000 scanning probe microscope (Digital Instrument) using a rectangular 225-mm Si cantilever. The stiffness of the cantilever was ˜4 N/m with a resonance frequency of ˜70 kHz. The free vibration amplitude was high, in the range of 80 nm to 100 nm, with a RMS setting of 3.8 volts. While the set point ratio was maintained at a value equal to or lower than 0.5, the contact set point was adjusted routinely to ensure repulsive contacts with positive phase shifts. The cantilever was running at or slightly below its resonance frequency.

AFM phase images of all specimens were converted into a TIFF format and processed using PHOTOSHOP (Adobe Systems, Inc.). The image processing tool kit (Reindeer Games, Inc.) was applied for image measurements. Results of image measurements were written into a text file for subsequent data processing using EXCEL (Microsoft) or MATLAB (MathWorks, Inc.) for computing sizes/shapes of dispersed phases, co-continuity factor of co-continuous phases, or nearest-neighbor inter-particle distances.

Transmission Electron Microscopy (TEM) was used to study details of the interface between the ethylene/propylene/diene rubber and the semi-crystalline polypropylene phases. The instrument used was the JEOL 2000FX microscope. A heavy metal staining technique was employed to provide contrast to delineate the details of the sample morphology. Ruthenium tetroxide provides excellent contrast between amorphous and crystalline regions and was used. Lower density and amorphous polymers take up more stain than do higher density and more crystalline components. Thus heavily stained components appear darker in TEM amplitude contrast images whereas less heavily stained materials appear lighter. The TEM analytical method used involved:

-   -   Setting the orientation of the plane of analysis. Typically the         MD-ND (machine direction/normal direction) plane is preferred         for samples that may be oriented in the machine direction.     -   Creating a deformation-free face through the bulk polymer sample         using a cryomicrotome.     -   Staining with ruthenium tetroxide vapor for about 8 hours.     -   Cutting and collecting ultrathin (about 100 nm) sections from         the stained face using an ultramicrotome. The cutting is done         using a diamond knife. Sections are floated onto TEM grids.     -   Loading sections into the TEM for examination at the appropriate         accelerating voltage (typically 160 to 200 kV).     -   Examining the sections to determine level of sampling needed.     -   Acquiring digital images using appropriate vendor software.

The ethylene content of ethylene/propylene copolymers was determined using FTIR according to the following technique. A thin homogeneous film of polymer, pressed at a temperature of about 150° C., was mounted on a Perkin Elmer Spectrum 2000 infrared spectrophotometer. A full spectrum of the sample from 600 cm⁻¹ to 4000 cm⁻¹ was recorded and the area under propylene band at ˜1165 cm⁻¹ and the area of ethylene band at ˜732 cm⁻¹ in the spectrum were calculated. The baseline integration range for the methylene rocking band is nominally from 695 cm⁻¹ to the minimum between 745 and 775 cm⁻¹. For the polypropylene band the baseline and integration range is nominally from 1195 to 1126 cm⁻¹. The ethylene content in wt. % was calculated according to the following equation: ethylene content(wt. %)=72.698−86.495X+13.696X ² where X=AR/(AR+1) and AR is the ratio of the area for the peak at ˜1165 cm⁻¹ to the area of the peak at ˜732 cm⁻¹.

Solvent extraction was used to isolate the different polymer species of the in-reactor polymer blends. The fractionations were carried out in a two-step successive solvent extraction when the polymer blend did not contain any oil: one involves cyclohexane extraction, the other xylene Soxhlet extraction. In the cyclohexane solvent extraction, about 0.3 gram of polymer was dissolved in about 60 ml of cyclohexane to isolate the uncured and lightly branched elastomeric components of the polymer blend. The mixture was continuously stirred at room temperature for about 48 hours. The soluble fraction (referred as cyclohexane solubles) was separated from the insoluble material (referred as cyclohexane insolubles) using filtration under vacuum. The insoluble material was then subjected to the xylene soxhlet extraction procedure. In this step, the insoluble material from the room temperature cyclohexane extraction was first extracted for about 24 hours with xylene. The xylene insoluble portion (referred as xylene insolubles) was recovered by filtration and is the extract containing the at least partially cross-linked second polymer. The remaining portion was cooled down to room temperature and retained in a glass container for 24 hours for precipitation. The precipitated component (referred as xylene precipitate) was recovered through filtration and the soluble component (referred as xylene soluble) was recovered by evaporating the xylene solvent. The xylene precipitate fraction is where the thermoplastic crystalline component resides. In the case of blends containing paraffinic oil, plasticizer and the like, another Soxhlet solvent extraction step was performed on the sample for 24 hours to isolate the oil from the blend before the cyclohexane extraction and xylene Soxhlet extraction using an azeoptrope of acetone and cyclohexane in the ratio 2:1 by volume. The soluble fraction is referred as to azeoptrope solubles.

In order to measure the physical properties of the polymer blends, samples were first mixed in a Brabender melt mixer with ˜45 mL mixing head. The polymer was stabilized with antioxidant during mixing in the Brabender. The Brabender was operated at 100 rpm and at temperature of 180° C. Mixing time at temperature was 5-10 minutes, after which the sample was removed from the mixing chamber. The homogenized samples were molded under compression into film on a Carver hydraulic press for analysis. About 7 grams of the homogenized polymer were molded between brass platens lined with Teflon™ coated aluminum foil. A 0.033 inch (0.08 cm) thick chase with a square opening 4 inch×4 inch (10.2×10.2 cm) was used to control sample thickness. After one minute of preheat at 170° C. or 180° C., under minimal pressure, the hydraulic load was gradually increased to 10,000 to 15,000 lbs, at which it was held for three minutes. Subsequently the sample and molding plates were cooled for three minutes under 10,000 to 15,000 lbs load between the water-cooled platens of the press. Plaques were allowed to equilibrate at room temperature for a minimum of 24 hours prior to physical property testing.

β relaxation, Loss Modulus (E″) and Storage Modulus (E′) were measured by dynamic mechanical thermal analysis (DMTA). The instrument used was the RSA II, Rheometrics Solid Analyzer II from TA Instruments, New Castle, Del. The instrument was operated in tension mode and used molded rectangular samples. Sample conditions were: 0.1% strain, 1 Hz frequency, and 2° C. per minute heating rate, covering the temperature range from −135° C. to the melting point of the sample. Samples were molded at about 200° C. Typical sample dimensions were 23 mm length×6.4 mm width×thickness between 0.25 mm and 0.7 mm, depending on the sample. Tan δ is the ratio of E″/E′. The output of these DMTA experiments is the storage modulus (E′) and loss modulus (E″). The storage modulus measures the elastic response or the ability of the material to store energy, and the loss modulus measures the viscous response or the ability of the material to dissipate energy. The ratio of E″/E′ (=tan δ) gives a measure of the damping ability of the material. Energy dissipation mechanisms (i.e., relaxation modes) show up as peaks in tan δ, and are associated with a drop in E′ as a function of temperature. The uncertainty associated with reported values of E′ is expected to be on the order of ±10%, due to variability introduced by the molding process.

Shore hardness was determined according to ISO 868 at 23° C. using a Durometer.

Stress-strain properties such as ultimate tensile strength, ultimate elongation, and 100% modulus were measured on 2 mm thick compression molded plaques at 23° C. by using an Instron testing machine according to ISO 37.

Compression set test was measured according to ISO 815A.

Tension set was measured according to ISO 2285.

Oil swell (oil gain) was determined after soaking a die-cut sample from compression molded plaque in IRM No. 3 fluid for 24 hours at 125° C. according to ASTM D 471.

Viscosity was measured using LCR (Laboratory Capillary Rheometer) according to ASTM D 3835-02 using a Dynisco Capillary rheometer at 30:1 L/D (length/diameter) ratio, a shear rate of 1200 l/s and a temperature of 204° C. The entrance angle of the laboratory capillary rheometer is 180°, barrel diameter is 9.55 mm. The heat soak time is 6 minutes.

Examples 1A to 1C

Three polymer blends were produced in a two-stage polymerization reaction by polymerizing propylene in a first stage to make homopolymer, and copolymerizing propylene and ethylene as well as a diene cross-linking agent in a second stage in the presence of the homopolymer produced in the first stage. The polymerization was carried out in an autoclave reactor equipped with a stirrer, an external water/steam jacket for temperature control, a regulated supply of dry nitrogen, ethylene, propylene, and a septum inlet for introduction of other solvents, catalysts and scavenger solutions. The reactor was first washed using hot toluene and then dried and degassed thoroughly prior to use. All the solvents and monomers were purified by passing through a 1-liter basic alumina column activated at 600° C., followed by a column of molecular sieves activated at 600° C. or Selexsorb CD column prior to transferring into the reactor.

In the first stage of polymerization, triisobutyl aluminum (TIBAL) (25 wt % in hexane, purchased from Sigma-Aldrich) solution was first added to the reactor. Then the catalyst solution was cannulated into the reactor using solvent. In succession, solvent (diluent) and propylene were added into the reactor. All of these were conducted at room temperature. The mixture was then stirred and heated to a desired temperature. The first stage of polymerization was ended when the desired amount of polypropylene was produced, determined by monitoring the reactor pressure during the reaction. Thereafter, the reactor was depressurized by venting the unreacted propylene and solvent to the atmosphere until the reactor pressure reached about 5 psig (34.5 kPa) to maintain an inert atmosphere in the reactor for the continuation of polymerization in the second stage.

In the second stage of polymerization, propylene was added into the mixture produced in the first stage. The mixture was then stirred and heated to a desired reaction temperature. In succession, diene and ethylene were added into the reactor. The ethylene was fed on demand to maintain a relative constant reactor pressure during the polymerization reaction. The ethylene consumption was monitored during the reaction using a mass flow meter. The polymerization reaction was terminated when desired amount of rubber was produced. Thereafter, the reactor was cooled down and unreacted monomer and solvent (diluent) were vented to the atmosphere. The resulting mixture, containing mostly solvent, polymer and unreacted monomers, was collected in a collection box and first air-dried in a hood to evaporate most of the solvent, and then dried in a vacuum oven at a temperature of about 90° C. for about 12 hours.

1,9-decadiene was used as the diene cross-linking agent in the second polymerization stage. The 1,9-decadiene was obtained from Sigma-Aldrich and was purified by first passing through an alumina column activated at high temperature under nitrogen, followed by a molecular sieve activated at high temperature under nitrogen.

Rac-dimethylsilyl bis(2-methyl, 4-phenylindenyl)zirconium dimethyl catalyst preactivated with N,N-dimethylanilinium tetrakis (pentafluorophenyl) borate (both obtained from Albemarle) at a molar ratio of about 1:1 in toluene was fed into the reactor in Stage 1. Example 1A and 1C were conducted in a 0.5-liter autoclave reactor with no additional catalyst being added in Stage 2. Example 1B was produced in a 1-liter autoclave reactor with additional catalyst added in the second stage of polymerization. No reactor depressurization was used at the end of stage 1 and no additional propylene was added into the reactor in the second stage in Example 1B. Details of the experimental conditions, catalysts employed and the properties of the resultant polymer blends are listed in Table 1A below. TABLE 1A Example # 1A 1B 1C Polymerization in Stage 1 Reaction temperature (° C.) 70 70 70 Amount of catalyst (mg) 2 0.5 2 Propylene #1 (ml) 125 500 125 Hexane (ml) 125 700 125 TIBAL (25 wt. %) (ml) 0.5 4 0.5 Reaction time in stage 1 (min) 15 3.2 15 Polymerization in Stage 2 Reaction temperature (° C.) 70 85 70 Amount of catalyst (mg) 0 0.72 0 Propylene #2 (ml) 100 0 70 Ethylene head pressure (psi) 100 180 100 1,9 decadiene (ml) 0.3 6 100 Hexane (ml) 0 100 0.1 Reaction time in stage 2 (min) 60 28 60 Yield (g) 78.8 151.7 99.9 Tc (° C.) 119.8 109.4 121.5 Tm (° C.) 155.9 156.9 155.6 Heat of fusion (J/g) 36.3 24.6 60.4 Tg (° C.) −50.1 −35.4 −46.6 Ethylene content (wt %) 22.6 19.1 19.5 Xylene precipitate (wt %) 44.4 27.3 76.4 Xylene insolubles (wt %) 27.2 40.2 1.0 Xylene solubles (wt %) 10.2 7.7 7.5 Cyclohexane solubles (wt %) 18.2 24.9 15.1 Degree of cross-link (%) 48.9 55.3 4.1

Degree of cross-link is defined as: Degree of cross-link=Percent of xylene insoluble/100−percent of xylene precipitate×100

The Tg values shown in the table above refer to the elastomer component in the reactor-produced blend examples. The values provide an indication of the amorphous nature of the elastomer component; thus Example 1A which contains a higher level of ethylene comonomer appears more amorphous than Example 1B with a higher Tg. The Tg of the polypropylene component—located primarily in the xylene precipitate fraction—is generally about 0° C., typical for semi-crystalline propylene homopolymers.

The two polymer blends produced in Examples 1A and 1B were subjected to solvent extraction. The amount of each extracted fraction is expressed as the weight percent of the total polymer blend and is listed in Table 1A. Some of the physical properties of these fractionated components are listed in Table 1B and 1C. TABLE 1B Physical properties for the fractions obtained through solvent extraction for Example 1A Cyclohexane Xylene Xylene Xylene Fraction solubles Insolubles Precipitates Solubles Tc (° C.) 15.0 Tm (° C.) 146 154 Tg (° C.) −50.9 Heat of 35 fusion (J/g) Mn (kg/mol) 26.4 Mw (kg/mol) 72.8 Mz (kg/mol) 273.5 g'vis 0.84 Ethylene content (wt %)

TABLE 1C Physical properties for the fractions obtained through solvent extraction for Example 1B xylene cyclohexane cyclohexane xylene precip- xylene Fraction solubles insolubles insolubles itates solubles Tc (° C.) 12.8 Tm (° C.) 65.0 Tg (° C.) −40.5 Heat of 3.3 fusion (J/g) Mn (kg/mol) 11.4 196.5 69.8 Mw (kg/mol) 34.0 432.5 225.1 Mz (kg/mol) 92.6 877.9 955.9 g'vis Ethylene 25.7 16.9 content (wt %)

The polymer blends produced in Examples 1A and 1B were melt mixed and molded under compression into plaques, and tested for thermoplastic elastomer applications. Examples 1B was also compounded with about 30% of Sunpar 150 M oil at an elevated temperature in a Brabender mixer, and molded under compression into plaques, and tested for thermoplastic elastomer applications. The performance data are listed in Table ID. TABLE 1D Performance data for Examples 1A and 1B Polymer 1A 1B 1B Polymer (%) 100 100 70 Oil (Sunpar 150 M) (%) 0 0 30 Hardness (SHORE) 33D 72A 49A Ultimate tension strength (psi) 2101 1144 542 (ISO37) Ultimate elongation (%) (ISO37) 153 332 340 100% Modulus (psi) 1953 673 274 Viscosity (Pa-s) 135 179.6 75.6 Tension set (%) (ISO2285) 7.5 19.75 15.75 Compression set, 70° C./22 Hrs (%) 62.18 62.74 48.47 (ISO815A) Weight gain, 121° C./24 hrs (%) 330.16 495.15 380.2

The morphology of each of the blends produced in Examples 1A and 1B was examined using AFM according to the procedure described above and the results are shown in FIGS. 1A and 1B. It was observed that the rubber was in the discrete particle phase embedded in polypropylene matrix. The particle size of the dispersed phase varied in a range of 0.04 to 3 μm with an average particle size of about 0.48 μm for the dispersed phase of the blend of Example 1A (see FIG. 1D). The particle size at the lower end was estimated due to the limitation of AFM image resolution. The presence of sub-micrometer particles is illustrated in the TEM image shown in FIG. 1C. The particle size distribution of the dispersed phase at the lower end of particle size was analyzed using TEM image. As an example, FIG. 1E shows the data obtained from the TEM image of Example 1A.

DSC melting and crystallization on the xylene insoluble fraction from Example 1B is shown in FIG. 1F. The xylene insoluble fraction is mainly crosslinked elastomer produced in the reactor. The DSC first heating shows the presence of an exotherm starting at about 175° C. This exotherm is unexpected, because it occurs during heating and because the sample fraction contains primarily crosslinked rubber. Generally, crystallization (of a propylene polymer in this case) would be suspected from the presence of an exotherm. This is however unlikely, given that it occurs at such a high temperature. It is believed that this exotherm reflects shrinkage in the sample. Some of the crosslinked elastomer appears to be linked to a small amount of polypropylene, which constrains its movement. Following the melting of the polypropylene (complete by about 175° C.), mobility is regained and the elastomer is able to shrink. Subsequent crystallization and 2nd heating of this fraction also exhibit a response, as is seen by baseline changes at about this temperature. This observation points to the capability of the process to produce cross products, which offer novel product features (in this case unexpected high levels of shrinkage).

In addition to the capability offered by the process to form novel cross products, unique morphologies are noted in the polypropylene matrix. An example of such a morphology is shown in FIG. 1G. This TEM micrograph is of Example 1C. FIG. 1G shows the uniform, fine-sized rubber particles delivered by the process (largest dimension ˜0.2 μm). This is to be compared against a size generally 0.5 μm or larger for current commercial TPVs via dynamic vulcanization, as shown in FIG. 1H, which is are TEM representations for Santoprene grade 201-55 (available from Advanced Elastomer Systems in Akron, Ohio). Additionally, the micrograph of FIG. 1G shows the presence of spherulites with transverse oriented lamellae, different from the more usual radially-oriented lamellae. The presence of these transverse spherulites in metallocene polypropylene has been related to the gamma phase or polymorph of polypropylene crystals (reference: R. G. Alamo and coworkers, Polymer, 45, 3441-3455, 2004). The presence of gamma phase crystallites, along with the more common alpha form, provides a broadened melting range. This offers benefits for the blends of this invention in certain thermoplastic fabricating operations (e.g. thermoforming).

Examples 2A to 2C

These three samples were produced in a 2-liter autoclave reactor equipped similarly to the 0.5 liter reactor described in Examples 1A and 1B. These examples demonstrate a two-stage polymerization reaction with the use of rac-dimethylsilyl bis(2-methyl-4-phenylindenyl)zirconium dimethyl catalyst (Catalyst A) in the first stage to produce polypropylene and [di(p-triethylsilylphenyl)methylene](cyclopentadienyl) (3,8-di-t-butylfluorenyl)haffiium dimethyl catalyst (Catalyst B) (obtained from Albemarle) in the second stage to produce ethylene propylene diene rubber. Both catalysts were preactivated by dimethylanilinum tetrakis(heptafluoro-2-naphthyl) borate at a molar ratio of 1:1 in toluene. The general procedure described above in Examples 1A and 1B was followed with the following exceptions: (1) tri-n-octylaluminum (TNOA) (25 wt. % in hexane, Sigrna Aldrich) was used as a scavenger; (2) no reactor depressurization at the end of stage 1; (3) about 6 ml of air was injected into the reactor at the end of stage 1 to deactivate the Catalyst A and then additional 5 ml of TNOA was injected at about 10 minutes after; (4) the second stage polymerization started with ethylene addition and diene was injected after ethylene introduction; (5) Catalyst B was injected into reactor in stage 2 right after diene addition. The detailed reaction condition and polymer properties are listed in Table 2A. TABLE 2A Example # 2A 2B 2C Polymerization in Stage 1 Reaction temperature (° C.) 75 75 75 Amount of catalyst A (mg) 0.60 0.50 0.50 Propylene #1 (ml) 700 700 700 Toluene (ml) 500 500 500 TNOA (25 wt %) (ml) 8.0 8.0 8.0 Reaction time in stage 1 (min) 11.0 7.0 7.0 Polymerization in Stage 2 Reaction temperature (° C.) 75 75 80 Amount of catalyst B (mg) 1.20 1.00 1.10 Propylene #2 (ml) 0 0 0 Ethylene head pressure (psi) 230 250 250 1,9 decadiene (ml) 47.0 50.0 50.0 Toluene (ml) 300 300 300 Reaction time in stage 2 (min) 22 8 19 Yield (g) 57.3 53.1 119.0 Tc (° C.) 109.3 111.4 102.4 Tm (° C.) 157.8 155.3 150.6 Heat of fusion (J/g) 50.6 40.0 22.8 Tg (° C.) −46.4 −48.1 −44.0 Ethylene content (wt %) 22.4 Xylene precipitate (wt %) 45.03 45.03 22.73 Xylene insolubles (wt %) 23.12 29.73 60.08 Xylene solubles (wt %) 22.43 18.39 11.23 Cyclohexane solubles (wt %) 9.42 6.85 5.97 Degree of cross-link (%) 42.1 54.1 77.8

The polymer blends produced in Examples 2A to 2C were subjected to solvent extraction. The amount of each fraction is listed in Table 2A. Some of the physical properties of the fractionated components for the polymer blend of Example 2C are listed in Table 2B. TABLE 2B Physical properties for the fractions obtained through solvent extraction for Example 2C Xylene Insoluble film Cyclohexane without Xylene Xylene Fraction Solubles filler Precipitate Solubles Tc (° C.) 117.46 Tm (° C.) 154.98 Tg (° C.) Heat of 114.10 fusion (J/g) Ethylene 27.7 content (wt %)

The polymer blends produced in Examples 2A to 2C were melt mixed and molded under compression into plaques, and tested for thermoplastic elastomer applications. Example 2C was also formulated with Paralux 6001R oil during the melt mixing. The performance data are listed in Table 2C. TABLE 2C Performance data for Examples 2A to 2C Polymer 2A 2B 2C 2C Polymer (%) 100.0 100.0 100.0 69.93 Oil (Paralux 6001R) (%) 0 0 0 30.07 Hardness (SHORE) 88A 91A 75A 57A Ultimate tension strength 2037 2330 1255 617.4 (psi) (ISO37) Ultimate elongation 286 364 125 203.8 (%) (ISO37) 100% Modulus (psi) 1517 1704 1138 356.1 Viscosity (Pa-s) NA NA NA 198.7 Tension set (%) 36.5 39.2 15 8.5 (ISO2285) Compression set, 55.1 56.9 29.4 27.6 70° C./22 Hrs (%) (ISO815A) Weight gain, 121° C./ 171.3 186.1 254.9 235.0 24 hrs (%)

A transmission electron micrograph of a molded part cross-section produced from the polymer blend of Example 2C is shown in FIG. 2A.

Reactor blend Examples 1A and 2C were analyzed by small angle oscillatory shear experiments. This rheological analysis provides data on the viscoelastic properties of the polymer blends. Measurements include those of the storage and loss modulii (G′, G″) over a range of frequencies, at a given melt temperature. The Theological data were analyzed using the Van Gurp-Palmen treatment (reference: M. Van Gurp and J. Palmen, Rheology Bulletin, 67, 5, 1998), whereby the phase angle δ(=tan⁻¹ (G″/G′)) is plotted against the absolute value of the complex modulus |G*|=(G′²+G″²)^(1/2). This representation of linear viscoelastic data is a powerful means of characterizing molecular and structural features of polymers. For example, low levels of long chain branching in polyolefins can be detected and quantified on a relative basis, using this methodology. The data are shown in FIG. 2C. The figure shows the region of δ vs |G*| where current commercial Santoprene grades (from Advanced Elastomer Systems in Akron, Ohio) reside. These products are TPVs produced via dynamic vulcanization.

Example 3A

This example demonstrates a series dual-reactor continuous solution process with the use of rac-dimethylsilyl bis(2-methyl-4-phenylindenyl)zirconium dimethyl catalyst (Catalyst A) in the first reactor to produce polypropylene and [di(p-triethylsilylphenyl)methylene](cyclopentadienyl) (3,8-di-t-butylfluorenyl)haffium dimethyl catalyst (Catalyst B) in the second reactor to produce ethylene/propylene/diene copolymer. Polymerization was performed in a series dual-reactor continuous solution process. Both of the reactors were 0.5-liter stainless steel autoclave reactors and were equipped with a stirrer, a water-cooling/steam-heating element with a temperature controller, and a pressure controller. Solvents, monomers such as ethylene and propylene were first purified by passing through a three-column purification system. The purification system consisted of an Oxiclear column (Model # RGP-R1-500 from Labclear) followed by a 5A and a 3A molecular sieve columns. Purification columns were regenerated periodically whenever there was evidence of lower activity of polymerization. Both the 3A and 5A molecular sieve columns were regenerated in-house under nitrogen at a set temperature of 260° C. and 315° C., respectively. The molecular sieve material was purchased from Aldrich. Oxiclear column was regenerated in the original manufacture.

The solvent feed to the reactors was measured by a mass-flow meter. A Pulsafeed pump controlled the solvent flow rate and increased the solvent pressure to the reactors. The compressed, liquefied propylene feed was measured by a mass flow meter and the flow was controlled by a Pulsafeed pump. The diene was fed into the reactor through an Eldex pump and the flow rate was measured using a Micro-Motion Coriolis-type flow meter. The solvent, monomers and diene were fed into a manifold first. Ethylene from in-house supply was delivered as a gas solubilized in the chilled solvent/monomer mixture in the manifold. The mixture of solvent and monomers were then chilled to about −15° C. by passing through a chiller prior to feeding into the reactor through a single tube. Ethylene flow rate was metered through a Brookfield mass flow controller.

Catalyst A was preactivated with dimethyl anilinium tetrakis(heptafluoro-2-naphthyl) borate. The catalyst B was preactivated with N,N-dimethylanilinium tetrakis(pentafluorophenyl) borate. Both of them were preactivated at a molar ratio of 1:1 in 700 ml of toluene. All catalyst solutions were kept in an inert atmosphere with <1.5 ppm water content and fed into reactors by metering pumps. Tri-n-octylaluminum (TNOA) solution was used as a scavenger.

The reactors were first cleaned by continuously pumping solvent (e.g., hexane) and scavenger through the reactor system for at least one hour at a maximum allowed temperature (about 150° C.). After cleaning, the reactors were heated/cooled to the desired temperature using water/steam mixture flowing through the reactor jacket and controlled at a set pressure with controlled solvent flow. Monomers and catalyst solutions were then fed into the reactor. An automatic temperature control system was used to control and to maintain the reactors at set temperatures. Onset of polymerization activity was determined by observations of a viscous product and lower temperature of water-steam mixture. Once the activity was established and system reached steady state, the reactors were lined out by continuing operating the system under the established condition for a time period of at least five times of mean residence time prior to sample collection. The resulting mixture from the second reactor, containing mostly solvent, polymer and unreacted monomers, was collected in a collection box. The collected samples were first air-dried in a hood to evaporate most of the solvent, and then dried in a vacuum oven at a temperature of about 90° C. for about 12 hours. The vacuum oven dried samples were weighed to obtain yields. All the reactions were carried out at a pressure of about 2.41 MPa-g.

Propylene, solvent, Catalyst A solution and scavenger were fed into the first reactor. The content of the first reactor flows into the second reactor. Catalyst B solution, ethylene and diene were fed into the second reactor. The detailed reaction conditions and polymer properties are listed in Table 3A. TABLE 3A 1st reactor 2nd reactor Polymerization 80 110 temperature (C.) Propylene feed 14 0 rate (g/min) Ethylene feed 0 6 rate (SLPM) 1,9 decadiene 0 0.108 feed rate (ml/min) Toluene feed 80 rate (ml/min) Catalyst B feed 0 4.61 × 10⁻⁸ rate (mole/min) Catalyst A feed 4.16 × 10⁻⁸ 0 rate (mole/min) Yield (g/min) 11.5 Tc (° C.) 111.3 Tm (° C.) 157.1 Tg (° C.) −49.0 Heat of 25.8 fusion (J/g)

Examples 4A to 4C

These three samples were produced in a 2-liter autoclave reactor equipped similarly to the 0.5-liter reactor described in Example 1A. Catalysts used were rac-dimethylsilyl bis(2-methyl-4-phenylindenyl)zirconium dimethyl catalyst (Catalyst A) in the first stage to produce polypropylene and [di(p-triethylsilylphenyl)methylene](cyclopentadienyl) (3,8-di-t-butylfluorenyl)hafniium dimethyl catalyst (Catalyst B) in the second stage to produce ethylene propylene diene rubber. Both catalysts were preactivated by dimethylanilinum tetrakis(heptafluoro-2-naphthyl) borate at a molar ratio of about 1:1 in toluene. The procedure described above in Example 2A to 2C was followed except that 5-vinyl-2-norbornene (VNB) was used as the cross-linking agent in the second stage of polymerization. VNB was obtained from Sigma-Aldrich and was purified by first passing through an alumina column activated at high temperature under nitrogen, followed by a molecular sieve activated at high temperature under nitrogen. The detailed reaction conditions and polymer properties are listed in Table 4A. TABLE 4A Example # 4A 4B 4C Polymerization in Stage #1 Reaction temperature (° C.) 75 75 75 Amount of catalyst A (mg) 0.5 0.5 0.5 Propylene #1 (ml) 600 600 600 Toluene (ml) 500 500 500 TNOA (25 wt %) (ml) 3 3 3 Reaction time in stage 1 (min) 8 5.5 3 Polymerization in Stage #2 Reaction temperature (° C.) 75 75 75 Amount of catalyst B (mg) 1.5 1.6 2 Propylene #2 (ml) 100 100 100 Ethylene head pressure (psi) 230 230 230 VNB (ml) 10 20 40 Toluene (ml) 300 300 300 TNOA (25 wt. %) (ml) 10 10 10 Reaction time in stage 2 (min) 48 37 20 Yield (g) 56 101 104 Tc (° C.) 113.7 111.0 111.1 Tm (° C.) 157.4 158.6 157.7 Heat of fusion (J/g) 28.8 35.5 49.0 Tg (° C.) −52.5 −51.2 −51.5 Xylene precipitate (wt. %) 61.5 45.1 51.2 Xylene insolubles (wt. %) 2.0 18.9 27.3 Xylene solubles (wt. %) 8.2 28.3 17.1 Cyclohexane solubles (wt. %) 28.3 7.6 4.5 Degree of cross-link (%) 5.1 34.5 56.0 (TNOA is tri-n-octyl-aluminum)

The polymer blends produced in Examples 4A to 4C were subjected to solvent extraction using the procedure described above. The amount of each fraction expressed as weight percent and the calculated degree of cross-link are listed in Table 4A.

The polymer blends produced in Examples 4A to 4C were melt mixed and molded under compression into plaques, and tested for thermoplastic elastomer applications. The performance data are listed in Table 4B. TABLE 4B Performance data for polymer blends produced in Examples 4A to 4C Polymer blend 4A 4B 4C Hardness 76A 87A 94A Ultimate tension strength (MPa) 3.90 11.14 17.54 Ultimate elongation (%) 292 403 468 100% Modulus (MPa) 3.72 8.78 11.60 Tension Set (%) 36.75 31.75 37.25 Compression set, 70° C./22 Hrs (%) 68.9 60.6 55.5 Weight gain, 121° C./24 hrs (%) 511.3 354.9 200.4

All documents described herein are incorporated by reference herein, including any priority documents and/or testing procedures to the extent they are not inconsistent with this text. While there have been described what are presently believed to be the preferred embodiments of the present invention, those skilled in the art will realize that other and further embodiments can be made without departing from the spirit of the invention, and is intended to include all such further modifications and changes as come within the true scope of the claims set forth herein. 

1. A heterogeneous polymer blend comprising: (a) a continuous phase comprising a thermoplastic first polymer having a crystallinity of at least 30%; and (b) a dispersed phase comprising particles of a second polymer different from the first polymer dispersed in said continuous phase, the second polymer having a crystallinity of less than 20% and being at least partially cross-linked, and the average particle size of the particles of the second polymer being less than 1 micron.
 2. The polymer blend of claim 1 wherein said thermoplastic first polymer is a homopolymer of a C₂ to C₂₀ olefin.
 3. The polymer blend of claim 1 wherein said thermoplastic first polymer is a copolymer of a C₂ to C₂₀ olefin with less than 15 wt % of at least one comonomer.
 4. The polymer blend of claim 1 wherein said thermoplastic first polymer comprises a polymer of propylene.
 5. The polymer blend of claim 1 wherein the second polymer is produced from a plurality of comonomers comprising at least one C₃ to C₂₀ olefin and at least one polyene.
 6. The polymer blend of claim 5 wherein said at least one polyene has at least two polymerizable unsaturated groups.
 7. The polymer blend of claim 5 wherein said plurality of comonomers comprise propylene and ethylene.
 8. The polymer blend of claim 1 wherein the average particle size of the particles of the second polymer is between about 50 nanometers and about 0.5 microns.
 9. The polymer blend of claim 1 wherein said dispersed phase comprises more than 50 wt % of the total heterogeneous polymer blend.
 10. A heterogeneous polymer blend comprising (a) a continuous phase comprising a thermoplastic first polymer having a crystallinity of at least 30%; and (b) a dispersed phase comprising particles of a second polymer different from the first polymer dispersed in said continuous phase, the second polymer having a crystallinity of less than 20% and being at least partially cross-linked, and the average particle size of the particles of the second polymer being less than 10 microns, wherein said polymer blend is substantially free of processing oil.
 11. The polymer blend of claim 10 wherein said thermoplastic first polymer is a homopolymer of a C₂ to C₂₀ olefin.
 12. The polymer blend of claim 10 wherein said thermoplastic first polymer is a copolymer of a C₂ to C₂₀ olefin with less than 15 wt % of at least one comonomer.
 13. The polymer blend of claim 10 wherein the second polymer is produced from a plurality of comonomers comprising at least one C₃ to C₂₀ olefin and at least one polyene.
 14. The polymer blend of claim 10 wherein the average particle size of the particles of the second polymer is less than 1 micron.
 15. The polymer blend of claim 10 wherein the average particle size of the particles of the second polymer is between about 50 nanometers and about 0.5 microns.
 16. A heterogeneous polymer blend comprising (a) a continuous phase comprising a thermoplastic first polymer that is at least partially crystalline; and (b) a dispersed phase comprising particles of a second polymer different from the first polymer dispersed in said continuous phase, wherein said dispersed phase comprises at least a fraction which is insoluble in xylene and which comprises less than 2,500 ppm of a curative.
 17. The polymer blend of claim 16 wherein said fraction insoluble in xylene comprises less than 100 ppm of a curative.
 18. The polymer blend of claim 16 wherein said fraction insoluble in xylene comprises at least is at least 4% of said dispersed phase.
 19. A process for producing a heterogeneous polymer blend comprising (a) a continuous phase comprising a thermoplastic first polymer that is at least partially crystalline; and (b) a dispersed phase comprising particles of a second polymer different from the first polymer dispersed in said continuous phase, the second polymer having a crystallinity less than that of the first polymer and being at least partially cross-linked, the process comprising: (i) polymerizing at least one first monomer to produce a thermoplastic first polymer that is at least partially crystalline; and (ii) contacting at least part of said first polymer with at least one second monomer and at least one polyene under conditions sufficient to polymerize said second monomer to produce said second polymer and simultaneously cross-link said second polymer such that the dispersed phase produced by said contacting (ii) comprises at least a fraction which is insoluble in xylene.
 20. The process of claim 19 wherein said polymerizing (i) is conducted in the presence of a catalyst and said contacting (ii) is conducted in the presence of the same catalyst.
 21. The process of claim 19 wherein said polymerizing (i) is conducted in the presence of a first catalyst and said contacting (ii) is conducted in the presence of a second catalyst different from the first catalyst.
 22. A process for producing a heterogeneous polymer blend, the process comprising: (a) selecting a catalyst capable of polymerizing a C₂ to C₂₀ olefin to produce a first polymer having at least 30% crystallinity; (b) contacting said catalyst with one or more C₂ to C₂₀ olefins at a temperature of at least 50° C. to produce a first polymer having at least 30% crystallinity; (c) contacting said first polymer and said catalyst with at least one C₃ to C₂₀ olefin and at least one polyene under conditions sufficient to polymerize said at least one C₃ to C₂₀ olefin to produce a second polymer and simultaneously cross-link said second polymer, whereby the product of said contacting (c) is a heterogeneous polymer blend comprising a continuous phase of the first polymer having at least 30% crystallinity and a discontinuous phase of particles of said second polymer having an average particle size less than 10 microns, said second polymer being at least partially cross-linked and comprising at least 15 wt % of said C₃ to C₂₀ olefin and at least 0.0001 wt % of said polyene.
 23. The process of claim 22 wherein the first polymer produced in said contacting (b) has at least 0.01% terminal unsaturation.
 24. The process of claim 22 wherein said C₂ to C₂₀ olefin comprises propylene.
 25. The process of claim 22 wherein said first polymer is contacted with ethylene together with said at least one C₃ to C₂₀ olefin and said at least one polyene in said contacting (c).
 26. The process of claim 22 wherein said polyene has at least two polymerizable unsaturated groups.
 27. The process of claim 22 wherein said catalyst selected in (a) is a single site catalyst comprising at least one catalyst component and at least one activator.
 28. The process of claim 27 wherein said catalyst component is a bridged bis-indenyl metallocene catalyst having a substituent on one or both of the 2- and 4-positions on each indenyl ring.
 29. A process for producing a heterogeneous polymer blend, the process comprising: (a) selecting a catalyst capable of polymerizing a C₂ to C₂₀ olefin to produce a first polymer having at least 30% crystallinity; (b) contacting said catalyst with one or more C₂ to C₂₀ olefins at a temperature of at least 50° C. to produce a first polymer having at least 30% crystallinity; (c) contacting said first polymer together with at least one C₃ to C₂₀ olefin and at least one polyene with a catalyst capable of polymerizing bulky monomers under conditions sufficient to polymerize said at least one C₃ to C₂₀ olefin to produce a second polymer and simultaneously cross-link said second polymer, whereby the product of said contacting (c) is a heterogeneous polymer blend comprising a continuous phase of the first polymer having at least 30% crystallinity and a discontinuous phase of particles of said second polymer having an average particle size less than 3 microns, said second polymer being at least partially cross-linked and comprising at least 15 wt % of said C₃ to C₂₀ olefin and at least 0.0001 wt % of said polyene.
 30. The process of claim 29 wherein the first polymer produced in said contacting (b) has at least 0.1% terminal unsaturation.
 31. The process of claim 29 wherein said C₂ to C₂₀ olefin comprises propylene.
 32. The process of claim 29 wherein said first polymer is contacted with ethylene together with said at least one C₃ to C₂₀ olefin and said at least one polyene in said contacting (c).
 33. The process of claim 29 wherein said polyene has at least two polymerizable unsaturated groups.
 34. The process of claim 29 wherein the particles of said second polymer blend produced in step (c), prior to any subsequent curing step, have a melting temperature of at least 100° C.
 35. The process of claim 29 wherein the catalyst selected in (a) is different from the catalyst employed in said contacting (c). 